Land Rover Defender Workshop 1993 Rover Manual

							LT230T TRANSFER GEARBOX 
DISMANTLE 
Transmission  brake removal  Intermediate 
shaft and gear  cluster  removal 
5. Release  stake nut from  recess  in intermediate 
shaft  and remove  stake nut and  discard. 
1. Remove two countersunk  screws and 6. Unscrew  the single  bolt and  remove  anti - 
withdraw  brake drum.  rotation 
plate at the  rear  face of the transfer 
2. Remove  four bolts  securing  the brake  back - box. 
plate;  the 
two bottom  fixings retain the oil 
catcher. 
NOTE: A  hexagonal type socket should be 
used  for these bolts. 
7. Tap  the intermediate  gear shaft  from the 
transfer  box. 
Bottom  cover removal 
3. Remove  the six bolts  and washers  retaining 
the  bottom  cover. 
4. Remove  the gasket  and bottom  cover. 
8. Lift out the  intermediate  gear cluster  and 
bearing  assembly. 
10 REISSUED: FEB 1993  
						

							9. Remove the O  rings  from the intermediate 
gear  shaft  and from  inside  the transfer  box 
and  discard. 
LT230T TRANSFER GEARBOX 
16. Remove  and discard  the oil seal  at the  front 
of  the  transfer  box casing  using service 
tool 
10. Remove  taper roller  bearings  and bearing  18G 1271 to prevent damage to the housing. 
spacer 
from the  intermediate  gear cluster 17. Drive out the  input  gear front  bearing  track. 
assembly. 
Input gear removal 
11. Remove  five bolts  and washers  retaining  the 
take 
- off cover. 
12. Remove  the cover  and gasket,  discard  the 
gasket. 
13. Remove the two countersunk  screws and 
detach  the main  shaft  bearing  housing. 
14. Remove  the gasket  and discard. 
15. Withdraw  the input  gear assembly. 
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							LT230T TRANSFER  GEARBOX 
22. Withdraw the centre  differential  and selector 
shaft/fork  assembly. 
High/low 
cross 
- shaft housing  removal  Centre 
differential  removal 
18. Remove the six bolts  and washers  retaining 21. Remove high/low selector shaft detent  plug, 
the  cross 
- shaft  housing  ground lead and  spring and retrieve  the ball  with a suitable 
retaining  clip.  magnet. 
19. Remove the cross - shaft  housing  and gasket 
discard  the gasket. 
Front  output  housing  removal 
20. 
Remove  the eight  bolts and washers  and 
detach  the output  housing  from the transfer 
box  casing,  taking care not to mislay  the 
dowel.  Remove  the gasket  and discard. 
Rear  output  housing  removal 
23. Remove six bolts  and washers  and detach  the 
rear  output  housing  and shaft  assembly 
from 
the transfer  casing. 
24. Remove  the gasket  and discard. 
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							LT230T TRANSFER GEARBOX 
Transfer case overhaul - reassembling 
29. If previously  removed, fit studs and dowels to 
front  face of the transfer  casing. Use new 
components  where necessary. 
NOTE: The  position  of the  radial  dowel 
blade  is set  in  line  with the circle  which  is 
formed 
by the  front  output  housing fixing 
damage.  Remove if replacements  are holes. 
required. 
26. Remove the magnetic  drain plug, copper 30. Refit magnetic  drain plug with new copper 
washer  and filler/level  plug. Discard  the  washer and tighten  to the  specified  torque, 
washer. 
Transfer  case, dismantle and overhaul 
25. Inspect  the studs  and dowels  for wear or 
loosely fit the filler/level  plug. 
27. Drive out differential  rear bearing  track. 
28. Clean all areas  of the  transfer  casing ensuring 
all  traces 
of Loctite are removed from faces 
and  threads. 
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							LT230T TRANSFER GEARBOX 
Rear output  housing dismantle and  overhaul 4. Remove  housing from the  vice  and drive  out 
the  output
-shaft,  by striking  the  flange  end  of 
5. Carefully  lever off the oil catch  ring  using  a 
6. Remove and discard  the seal  from  the  output 
2. Remove  output  flange  with circlip  attached. If housing  using  tool 18G  1271 to avoid 
damaging the  housing. 
1. Using  flange  wrench 18G1205  and socket  the  shaft. 
wrench,  remove  the  flange  nut, steel and felt 
washers,  Ensure  flange  bolts are fully  screwdriver in the 
slot provided. 
engaged  in the  wrench. 
necessary,  use  a 
two - legged puller. 
NOTE: The  circlip  need  only be released if 
the  flange  bolts  are to be replaced. 
7. Using circlip  pliers, remove  the circlip  retaining 
the  bearing. 
8. Drive  out  the  bearing from  the  rear of the 
housing. 
3. Remove  speedo - drive  housing.  This  can be 
eased 
out with a  screwdriver. 
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I  
						

							LT230T TRANSFER GEARBOX 
9. Remove  speedometer  gear (driven)  from its 
housing. 
10.  Remove  the O  ring  and oil seal  and discard. 
16. Carefully  coat the lips 
of the  seal  with clean 
grease  and refit oil catch  ring onto  output 
17.  Fit the  O  ring and oil seal  (lip side  inwards) 
to speedometer  housing. 
18.  Lubricate  the ‘O’ 
ring and  seal  with oil, 
19. Locate  speedometer  gear (driven)  in housing 
11. Slide off spacer  and speedometer  drive gear  housing. 
from  output  shaft. 
12.  Clean  all parts,  replace  the 
0 ring, oil seals, 
felt  seal  and flange  nut. Examine  all other 
parts 
wear  or  damage  and renew, if 
necessary.  and press  into position. 
Reassembling rear output housing 
13.  Press  output  bearing  into the housing. Do not 
use  excessive  force. 
To facilitate fitting the 
bearing,  heat the output  housing  case. 
(This is 
not  to exceed  100°C (212°F)). 
14. Retain  bearing  with circlip,  using circlip  pliers. 
15.  Pre
-grease  between  the seal  lips and  fit new 
seal,  lip side  leading,  using 
tool 18G1422.  The 
seal  should  just make  contact  with the bearing 
circlip. 
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							LT230T TRANSFER GEARBOX 
20. Slide 
drive  gear and spacer  on to the output  4. Secure 
hand press  MS47  in vice  with  collars 
shaft.  18G47BB 
- 1 and using  button  18G47BB/3 
21.  Locate 
output shaft into the bearing  in the  remove the rear  taper  bearing  and collars. 
housing  and drive 
into position. 
22. Locate  speedometer  gear (driven)  housing 
assembly  into the output  housing  and press  in 
until  flush  with the housing  face. 
5. Remove  the high  range  gear and bush,  taking 
care  not to disturb  the high/low  sleeve. 
6. Mark the relationship of the high/low  sleeve to 
the  hub  and  then remove  the sleeve. 
7. Using  a suitable  press behind  the low  range 
gear  carefully  remove the high/low  hub and 
low range  gear. 
Centre 
differential  unit dismantle  and overhaul 
1.  Secure  centre differential  unit 
to a vice fitted 
with soft jaws,  and release  stake nut from 
recess. 
2. Remove  stake nut using  tool 18G1423 and 
suitable  socket wrench  and discard  stake nut. 
3. Remove  the differential  unit from  the vice. 
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							LT230T TRANSFER GEARBOX 
8. Substituting collar LST47 - 1 remove  front 
taper  roller bearing  from the differential. 
9. Remove  hand press  from the vice. 
10. Using  soft jaws  secure  the differential  unit in 
the  vice  by gripping  the hub  splines. 
16. Inspect  all components  for damage  or wear, fit 
new  components if necessary. 
17. Using soft jaws  secure  the rear  (longest  half) 
of the differential  unit in the vice  by gripping 
the  hub  splines. 
18. Lubricate  and install  the cross  shafts  and 
pinion  gears with new dished  washers 
DO 
NOT 
fit  the  rear  bevel  gear at this  stage. 
11. Remove  the eight  retaining  bolts and lift off 
the  front  part 
of the differential  unit. 
12. Release the retaining  ring and  remove  front 
upper  sun gear  and thrust  washer. 
13. Remove  the planet  gears and dished  washers 
along  with the cross  shafts. 
14. Remove  the rear  lower  sun gear  and thrust 
washer  from the rear  part of the  differential 
unit. 
15. Remove  the rear  differential  unit from  the vice 
and  clean  all components. 
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							LT230T TRANSFER GEARBOX 
19. Lubricate and fit the front  bevel  gear and 
thinnest  thrust washer  (FRC6956  1.05mm). 
20.  Fit the  front  half of the  differential  casing 
ensuring  that the 
two engraved  arrows are 
aligned. 
21.  Fit securing  bolts and tighten 
to the correct 
torque  (see section  06 
- TORQUE VALUES). 
22. Lubricate  and insert  the rear  output  shaft into 
the  bevel  gear and check  that the gears  are 
free 
to rotate. 
NOTE:  Gears that have  been  run will rotate 
smoothly  and 
will require a torque  of 0.56 
Nm (5 in lb).  Equivalent  force using  a 
spring  balance: 
0.45 Kg (1 Ib). 
New gears  will rotate  with a notchy feel 
and 
will require  a torque  of not  more  than 
2.26 Nm (20 in Ib).  Equivalent  force using  a 
spring  balance: 
1.72 Kg (3.8  Ib). 
Keep  all components  well lubricated 
when 
carrying  out these  adjustments. 
24. Change  the thrust  washer  for a thicker  one if 
the torque  reading  is too  low.  Five  thrust 
washers  are available 
in 0.10 mm  steps 
ranging  from 
1.05 to 1,45  mm. 
25. Dismantle  the unit  when  the front  bevel  gear 
thrust  washer  is selected. 
26. Remove  and retain  the front  bevel  and thrust 
23. Fit the  transmission  brake drum to the  output  washer combination. 
drive  flange  and check  the torque  required 
to 27. Reassemble  the unit  with  the rear  bevel  gear 
rotate  the gears.  Tie a length  of string  around  and thinnest  thrust washer 
in position. 
the  brake  drum, attach  a spring  balance 
to the 28. Using soft jaws  secure  the front  (shortest  half) 
string  and carefully  tension the string  until a  of the  differential  unit in the  vice  by gripping 
load 
to turn is obtained,  Alternatively  use a  the hub  splines. 
torque  wrench  applied 
to the brake  drum  29. Repeat  the above  procedure to obtain  the 
flange  nut. Rotate  the drum  slowly  by hand  to 
correct thrust washer  for the  rear  bevel  gear. 
overcome  initial load when  using  either 
method.  Note that the illustration  RR2332E 
shows  checking  torque at rear  bevel  gear. 
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							LT230T TRANSFER GEARBOX 
Re-assembling centre differential 
30. Fit the  selected  thrust washer  and bevel  gear 
into  the rear  differential  unit. 
38. Fit the  low  range  gear, with its dog  teeth 
uppermost 
to the  differential  assembly. 
39. Press the high/low  hub on to the differential 
splines. 
40.  Slide  the high/low  selector sleeve 
on to the 
high/low  hub ensuring  that the alignment 
marks  are opposite  each other. 
41.  Fit the  bush  into 
the high range  gear so that 
the  flange  is fitted  on the  opposite  side of the 
gear 
to the  dog  teeth.  Slide the bushed  gear 
on  to the  differential  assembly with the dog 
teeth  down. 31. Assemble  both pinion  assemblies  and dished 
washers  onto their  respective  shafts and fit 
the  rear  differential  unit. Secure  the 
assemblies  with the retaining  ring. 
32.  Lubricate  all the  components. 
33.  Fit the  selected  thrust washer  and bevel  gear 
into  the front  upper  differential  unit. 
34.  Align  both units  as previously  described and 
secure  with the eight  bolts 
to the specified 
torque. 
35. Check  the overall  torque required  to turn  the 
differential.  This should  be approximately 
equal  to the  resistance 
of both  bevel  gears 
added  together. 
36. Locate  the front  differential  bearing onto the 
front,  upper  differential  shaft and press  into 
position  using larger  end of 
tool 18G1424  as 
shown. 
37. Invert  the differential  unit and  secure  in the 
vice. 
NOTE:  During  the following  sequences  all 
parts  should  be lubricated  as they  are 
fitted. 
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