Land Rover Lt230q Overhaul Rover Manual
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Page 71
TRANSFERBOX 44 OVERHAUL 24.Apply Hylosil RTV102sealant tomating flange of high/low selectorhousing. 25. Fithousing ensuring thathigh/low selector finger islocated inrecess inhigh/low selector shaft. 26. Fit6bolts andtighten to25 Nm (18lbf.ft). Intermediate gears1.Insert anew collapsible spacerinto intermediate gears,fitbearings intobearing tracks. 2. Wrap asuitable lengthofwire around intermediate gearsandusing assistance, lower gears intomain casing ensuring thatthey are meshing withinput...
Page 72
TRANSFERBOX OVERHAUL 45 3.Lubricate newOrings withrecommended oil and fitto intermediate shaftandmain casing. 4.Raise intermediate gearsuntildummy shaft LRT-41-004 canbeinserted fromfrontoutput housing sideofmain casing. 5. Fitintermediate shaft,driftshaft intoposition whilst atthe same timeexpelling dummyshaft LRT-41-004 . CAUTION:EnsureOring isnot displaced from main casing.
Page 73
TRANSFERBOX 46 OVERHAUL 6. Remove wirefrom around intermediate gears. 7.Rotate intermediate shaftuntilretaining plate can belocated onflat onshaft. 8. Apply Loctite 290tothreads ofretaining plate bolt. 9. Fitbolt and tighten to25 Nm (18lbf.ft). 10. Fitanew intermediate shaftnut. 11. Tighten intermediate shaftnutinsmall stages until allend-float isjust removed from intermediate gears. CAUTION:Checkend-float ofintermediate gears between eachstage, donot continue tightening nutafter end-float is removed....
Page 74
TRANSFERBOX OVERHAUL 47 6. When torque toturn figure -intermediate gear bearing pre-load iscorrect, stakeflange of intermediate shaftnutinto recess in intermediate shaft. 7. Remove toolLRT-41-005. NOTE: Discovery coverplateillustrated. 8.Remove 2bolts used totemporarily secure mainshaft inputgearbearing housing, remove housing. ApplyHylosil 2000sealant tomain casing mating faceofbearing housing, position housing onmain casing ensuring reference marks arealigned. 9. Apply Hylosil RTV102sealant tomating...
Page 75
TRANSFERBOX 48 OVERHAUL High/low selectorshaftdetent 1.Fitdetent balland spring. 2. Apply Loctite 290tothreads ofdetent plug. 3. Fitand tighten plugthen unscrew 2full turns. 4. Operate high/low selectorleverandcheck that detent ballcan befelt topositively engageand disengage withgrooves inselector shaft;screw plug inor out until setting iscorrect. Interlock solenoid-if fitted 1. Position solenoid inmain casing. 2. Apply Hylosil RTV102tomating faceof solenoid cover. 3. Fitsolenoid coverandBelleville...
Page 76
TRANSFERBOX OVERHAUL 49 Neutral warning lampswitch -if fitted 1. Apply Hylosil PL32sealant tothreads of switch. 2. Fitwasher, fitand tighten switch. Differential lockwarning lampswitch -adjust 1. Move differential lockselector forkto differential lockedposition. 2. Connect a12V testlamp andbattery to differential lockswitch. 3. Screw switchinuntil testlamp isilluminated then screw switch inafurther 1/2turn; tighten locknut. 4. Disengage differentiallock,check thattest lamp isextinguished. 5. Remove...
Page 77
TRANSFERBOX 50 OVERHAUL Transmission brake 1. Apply Hylosil RTV102sealant tomating face of rear output housing. 2.Position brakebackplate onrear output housing ensuring thatalignment marksare together. 3. Fit4bolts andtighten to70 Nm (52lbf.ft). 4. Fittransmission brakedrum, fitcountersunk screw andtighten.
Page 78
TRANSFERBOX DATA, TORQUE &TOOLS 1 DATA High/low selectorfingerwidth 15.90to15.95 mm .................. 0.625to0.627 in High/low selectorforkfinger width 7.37to7.47 mm ............... 0.290to0.294 in High/low selectorshaftgroove width 16.0to16.1 mm ............. 0.63to0.64 in High/low selectorhubgroove width 7.5to7.6 mm .............. 0.295to0.30 in Differential lockselector fingerwidth 15.90to15.95 mm ............. 0.625to0.627 in Differential lockselector shaftgroove width 16.0to16.1 mm ..........
Page 79
TRANSFERBOX 2 DATA,TORQUE &TOOLS TORQUE FIGURES Drain plug 30Nm ................................. 22 lbf.ft Differential carrierbolts 60Nm ....................... 44 lbf.ft Differential bearingnut 72Nm ....................... 53 lbf.ft Differential lockselector levernut 15Nm ............... 11 lbf.ft * Front andrear output housing bolts 25Nm ............ 18 lbf.ft Output flangenuts 162Nm ........................... 120 lbf.ft * Differential lockselector housing bolts 25Nm .......... 18 lbf.ft High/low...
Page 80
TRANSFERBOX DATA, TORQUE &TOOLS 3 SERVICE TOOLS LRT-37-11/2 Thrustbutton LRT-37-014 Mainshaftoilseal replacer LRT-41-001 Collars-differential rearbearing LRT-41-001 Thrustbutton LRT-41-002 Collars-differential frontbearing LRT-41-003 Mainshaftinputgearbearing remover/replacer LRT-41-004 Intermediategeardummy shaft LRT-41-005 Inputgearmandrel LRT-41-006 Intermediategearbearing trackreplacer LRT-41-007 Differentialbearingnutremover/replacer LRT-41-008 Differentialbearingreplacer LRT-41-011...