Land Rover Lt230q Overhaul Rover Manual
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DealerStamp Technical Information Review While everyattempt ismade toensure thatthetechnical information wesupply isas accurate anduptodate as possible, fromtimetotime, errors dooccur. Theremayalsobeinstances wherethestyle orcontent ofour publications donot meet yourexact needs. We would valueyourassistance inhelping ustoimprove thequality ofour publications andinvite youtosubmit details ofany technical errors,orimprovements youwould liketosee, inthe space below. Publication partnumber andedition ................................................................................................ ................. Publication title............................................................................................................... .................................... Section and/orpagesaffected ..................................................................................................... ...................... Technical information errors: Other improvements/changes youwould likeustoconsider: Service managers signature.......................................................................... Date ................................................................................................................... Please returnto: Technical Communication, RoverGroup AfterSales, POBOX 29, Cowley, Oxford,OX45NL
LT230Q TRANSFER BOX OVERHAUL MANUAL This transfer boxisfitted tothe following models: Serial No.Prefix 36Dand37D -Discovery Serial No.Prefix 38Dand40D -Defender Publication PartNo.LRL 0082ENG -2nd Edition Published byRover Technical Communication Ó1997 Rover Group Limited
INTRODUCTION CONTENTS Page INFORMATION INTRODUCTION 1 ...................................................................................................... REPAIRS ANDREPLACEMENTS 2 ........................................................................... SPECIFICATION 2 ......................................................................................................
INTRODUCTIONINTRODUCTION 1 INTRODUCTION How touse this manual To assist inthe use ofthis manual thesection titleis given atthe topand therelevant sub-section isgiven at the bottom ofeach page. This manual contains procedures foroverhaul ofthe LT230Q transferbox.Forallother information regarding adjustments andremoval ofoil seals, consult theRepair Manual forthe model concerned. This manual isdivided into3sections: Description andOperation,Overhaul andData,Torque &Tools. To assist filingofrevised information, each sub-section isnumbered frompage 1. Individual itemsaretobe overhauled inthe sequence inwhich theyappear inthe Manual. Items numbered inthe illustrations arereferred tointhe text.Overhaul operations includereference toService Tool numbers andtheassociated illustrationdepicts the tool. Where usageisnot obvious thetool is shown inuse. Operations alsoinclude reference to wear limits, relevant data,torque figures, specialist information anduseful assembly details. WARNINGS, CAUTIONSandNotes havethe following meanings: WARNING: Procedures whichmustbe followed precisely toavoid thepossibility of injury. CAUTION: Callsattention toprocedures which mustbefollowed toavoid damage to components. NOTE: Giveshelpful information. References Operations coveredinthis manual donot include reference totesting thevehicle afterrepair. Itis essential thatwork isinspected andtested after completion andifnecessary aroad testofthe vehicle iscarried outparticularly wheresafety related itemsareconcerned DimensionsThe dimensions quotedaretodesign engineering specification withService limitswhere applicable.
INTRODUCTION 2INTRODUCTION REPAIRS ANDREPLACEMENTS When replacement partsarerequired itis essential that only Land Rover recommended partsareused. Attention isparticularly drawntothe following points concerning repairsandthefitting ofreplacement parts andaccessories. Safety features andcorrosion prevention treatments embodied inthe carmay beimpaired ifother than Land Rover recommended partsarefitted. Incertain territories, legislation prohibitsthefitting ofparts not to the manufacturers specification. Torque wrench settingfigures giveninthis Manual must beused. Locking devices, wherespecified, must befitted. Ifthe efficiency ofalocking deviceis impaired duringremoval itmust berenewed. The terms ofthe vehicle Warranty maybe invalidated bythe fitting ofother thanLand Rover recommended parts.AllLand Rover recommended parts havethefullbacking ofthe vehicle Warranty. Land Rover Dealers areobliged tosupply onlyLand Rover recommended parts. SPECIFICATION Land Rover areconstantly seekingtoimprove the specification, designandproduction oftheir vehicles and alterations takeplace accordingly. Whileevery effort hasbeen made toensure theaccuracy ofthis Manual, itshould notberegarded asan infallible guide tocurrent specifications ofany particular component orvehicle. This Manual doesnotconstitute anoffer forsale of any particular component orvehicle. LandRover Dealers arenotagents ofthe Company andhave no authority tobind themanufacturer byany expressed or implied undertaking orrepresentation.
TRANSFERBOX CONTENTS Page DESCRIPTION ANDOPERATION FRONT OUTPUT HOUSING COMPONENTS 3 ......................................................... DIFFERENTIAL COMPONENTS 5 .............................................................................. MAIN CASING COMPONENTS 7 ............................................................................... REAR OUTPUT HOUSING ANDTRANSMISSION BRAKECOMPONENTS 9 .......... DESCRIPTION 11 ....................................................................................................... OPERATION 13 ........................................................................................................... OVERHAUL TRANSFER BOXDISMANTLING 1 ............................................................................ COMPONENT DISMANTLING 6 ................................................................................. High/low crossshafthousing 6 .................................................................................... Front output housing 7 ................................................................................................. Rear output housing 10 ................................................................................................ Main casing 12 ............................................................................................................. Mainshaft inputgearbearing housing 13 ..................................................................... Intermediate gears 13 .................................................................................................. Mainshaft inputgearassembly 14 ............................................................................... Differential lockselector 14 .......................................................................................... Differential 15 ............................................................................................................... INSPECTING COMPONENTS 18 ............................................................................... Intermediate gearsandshaft 18 .................................................................................. Mainshaft inputgear 19 ............................................................................................... High/low crossshaftandhousing 19 ........................................................................... Front output housing anddifferential lockselector 20 .................................................. Rear output housing 21 ................................................................................................ Main casing 22 ............................................................................................................. Mainshaft inputgearbearing housing 22 ..................................................................... High/low selectorforkand shaft 23 .............................................................................. Differential 24 ............................................................................................................... COMPONENT ASSEMBLING 25 ................................................................................ Differential 25 ............................................................................................................... Main casing 30 ............................................................................................................. Mainshaft inputgearbearing housing 31 ..................................................................... Mainshaft inputgearassembly 32 ............................................................................... Intermediate gears. 32 ................................................................................................. Rear output housing 33 ................................................................................................ Front output housing 35 ............................................................................................... High/low crossshafthousing 37 .................................................................................. Differential lockselector 37 .......................................................................................... TRANSFER BOXASSEMBLING 38 ............................................................................ Mainshaft inputgearbearing pre-load 38 .................................................................... Rear output housing 39 ................................................................................................ Differential bearingpre-load 40 .................................................................................... Front output housing 41 ............................................................................................... Intermediate gears 44 .................................................................................................. Intermediate gearbearing pre-load 46 ......................................................................... Bottom cover 47 ........................................................................................................... High/low selectorshaftdetent 48 ................................................................................. Interlock solenoid-if fitted 48 ......................................................................................