Land Rover Lt230q Overhaul Rover Manual

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24 OVERHAUL
Differential
1. Check sunand planet gearsforwear, cracks
and chipping ofteeth.
2. Check crossshafts andrecesses inboth
halves ofdifferential carrierfordamage and
wear.
CAUTION: Ensureplanetgearsare
retained withtheir respective shafts.
3.Check retaining ringfordistortion.
4. Check splines ofdifferential forwear and
damage.
5. Check teethofhigh/low hubforcracks,
chipping anduneven wear.
6.Check selector forkgroove widthinhigh/low
hub: Groove width=7.5 to7.6 mm (0.295 to0.3 in)
7....

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OVERHAUL 25
COMPONENT
ASSEMBLING
1. Lubricate allcomponents withrecommended
oil.
Differential 1. Lightly oilthreads ofdifferential bolts.
2.Secure rearhalfofdifferential carrierina
soft-jawed vice.
3. Fiteach planet geartoits respective
cross-shaft, fitnew dished thrustwasher to
each gear.
4. Fitcross-shafts, planetgearsanddished thrust
washers inrear halfcarrier.
CAUTION: Ensurethatcross-shafts arein
their correct fittedposition inrear half
carrier. Donot fitsun gear intorear half
carrier...

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26 OVERHAUL
14.
Check figureobtained againstspecified loadto
turn figure:
Used gears =0.45 kg(1.0 lb)
New gears =1.72 kg(3.8 lb)
15. Ifload toturn figure isbelow thatspecified,
proceed asfollows.
16. Remove frontoutput shafttogether withbrake
drum.
17. Remove 8bolts securing fronthalfdifferential
carrier.
18. Remove fronthalfdifferential carrier.
19. Remove fronthalfcarrier sungear andthrust
washer.
20. Select athicker thrustwasher fromtherange
available.
NOTE: 5thicknesses ofthrust washers...

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OVERHAUL 27
36.Invert assembly invice andthen insert rear
output shaftintorear halfcarrier, checkthat
gears rotate freely.
37. Fitoutput flangeontosplines ofoutput shaft,
do not fitflange nutatthis stage.
38. Fittransmission brakedrumtooutput flange,
secure with2nuts.
39. Carry outload toturn check usingsame
method asfor front halfcarrier.
40. When loadtoturn figure iscorrect, recordfinal
figure.
41. Upon completion, fitsun gear andselected
thrust washer tofront halfcarrier.
42. Fitfront...

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28 OVERHAUL
47.Support fronthalfcarrier inasoft-jawed vice.
48. Fitlow range gearensuring thatdog teeth on
gear aretowards threaded endofshaft.
NOTE: Useasuitable hollowmandrel tofit
gear ifitis tight onsplines.
49. Fithigh/low hubensuring thatalignment mark
made during dismantling istowards threaded
end ofshaft.
50. Fithigh/low selectorsleeveensuring that
alignment marksonhub andsleeve are
together.
51. Fitbush tohigh range gearensuring thatcollar
on bush ison opposite sideofgear tothe dog...

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OVERHAUL 29
55.Slide high/low selectorsleeveandhubaway
from lowrange gear.
56. Using feelergauges, determine clearance
between lowrange gearandhigh/low hub:
Clearance =0.05 to0.15 mm(0.002 to0.006
in)
57. Ifclearance isnot asspecified, fitanew low
range gearandhigh/low hubandre-check.58. Slide high/low selectorsleeveandhubaway
from highrange gear.
59. Using feelergauges, determine clearance
between highrange gearandhigh/low hub:
Clearance =0.05 to0.15 mm(0.002 to0.006
in)
60. Ifclearance...

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30 OVERHAUL
61.Using around nosed punch, stakecollarofnut
into recess indifferential shaft. Main
casing
1.Fitanew differential rearbearing trackusing
tool LRT-51-009.
2. Using astraight edgeandfeeler gauges, check
that bearing trackisrecessed 1.0mm (0.04 in)
below outerfaceofmain casing.
3.Using asuitable mandrel, fitanew mainshaft
input gearbearing track.
CAUTION: Ensurebearing tracksare
seated squarely inrecesses.    

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OVERHAUL 31
4.
Lubricate anew mainshaft oilseal with
recommended oil.
5.Invert maincasing andfitoil seal, lipside
facing inwards, usingtoolLRT-37-014. Mainshaft
inputgearbearing housing
1. Ensure bearing trackrecess inhousing is
clean.
2. Position a3.15 mm(0.12 in)thick shim in
bearing housing.
NOTE:Thisisthe thinnest ofthe shims
available.
3. Using asuitable mandrel, fitnew mainshaft
input gearbearing track.
CAUTION: Ensurebearing trackisseated
squarely inrecess.    

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32 OVERHAUL
Mainshaft
inputgearassembly
1. Lubricate newbearings withrecommended oil.
2.Secure handpress LRT-99-002 inavice.
3. Position collarsLRT-41-003 inhand press.
4. Position newbearing oncollars.
NOTE: Smallest diameter ofbearing must
be towards collars.
5.Locate endofmainshaft inbearing, press
mainshaft throughbearing.
6. Repeat aboveprocedure forremaining
bearing. Intermediate
gears.
1. Lubricate newbearings andbearing trackswith
recommended oil.
2.Fitnew circlips intointermediate...

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OVERHAUL 33
Rear
output housing
1. Heat rearoutput housing to100 °C (210 °F).
2. Fitnew output shaftbearing usingtool
LRT-41-011.
3. Allow housing toair cool.
4. Fitnew bearing retaining circlipensuring itis
seated ingroove. 5.
Lubricate anew output shaftoilseal with
recommended oil.
6.Fitoilseal using toolLRT-41-012.
NOTE: Useendoftool marked REARto
fit oil seal.
7.Check thatoilseal isjust contacting circlip.