Land Rover Lt230q Overhaul Rover Manual

							TRANSFERBOX
4 OVERHAUL
24.Remove 6bolts securing high/lowcrossshaft
housing.
25. Remove crossshafthousing.
CAUTION: Donot carry outfurther
dismantling ofcross shafthousing atthis
stage.
26. Slacken locknutandremove differential lock
warning lampswitch fromfrontoutput housing.
27. Clean sealant fromthreads ofswitch and
output housing.
28.Noting fittedposition oflongest bolt,remove 8
bolts securing frontoutput housing tomain
casing.
29. Remove frontoutput housing.
NOTE: Dowellocated.
CAUTION: Donot carry outfurther
dismantling offront output housing atthis
stage.    
						

							TRANSFERBOX
OVERHAUL 5
30.Noting theirfitted position, removeshoulder
bolt, 5bolts and2washers securing rear
output housing tomain casing.
31. Remove rearoutput housing.
NOTE: Dowellocated.
CAUTION: Donot carry outfurther
dismantling ofrear output housing atthis
stage.
32. Remove plugsecuring high/lowselectorshaft
detent springandball.
33. Remove detentspring.
34. Remove ballusing astick magnet.
CAUTION: Suitablyidentifyplug,detent
spring andballtotheir fitted positions, do
not interchange withdifferential lock
selector shaftdetent components.
Iffitted
35. Remove 4bolts securing interlocksolenoid
cover, remove coverandBelleville washer.
36. Remove interlocksolenoid.
37. Remove neutralwarning lampswitch and
washer.     
						

							TRANSFERBOX
6 OVERHAUL
Alltransfer boxes
38.Withdraw differential assemblytogetherwith
high/low selectorshaftandfork. COMPONENT
DISMANTLING
High/low crossshafthousing
1.Remove setscrew securinghigh/lowselector
finger tocross shaft.
2. Withdraw crossshaftfromhousing, recover
high/low selectorfinger.
3. Remove anddiscard Oring.   
						

							TRANSFERBOX
OVERHAUL 7
Front
output housing
1.Remove 7bolts securing differential lock
selector sidecover, remove cover.
2. Remove 3bolts securing differential lock
selector housing, removehousing andselector
as an assembly.
3. Remove anddiscard Oring from selector
housing.
4. Remove plugsecuring differential lockdetent
spring andball.
5. Remove detentspring.
6. Remove ballusing astick magnet.
CAUTION: Suitablyidentifyplug,detent
spring andballtotheir fitted positions, do
not interchange withhigh/low selector
shaft detent components.
7.Compress differential lockselector forkspring
and remove retaining clipfrom each endof
spring.
8. Withdraw differential lockselector shaftfrom
front output housing, recoverspring.
9. Remove differential lockselector fork.     
						

							TRANSFERBOX
8 OVERHAUL
10.Position propeller shaftflange holding tool
LRT-51-003 tooutput shaftflange.
11. Remove anddiscard self-locking nut.
12.Remove steelandfeltwashers, discardfelt
washer.
13. Remove outputshaftflange together withmud
shield.
NOTE: Areplacement outputflangewillbe
supplied withnewmud shield andoutput
shaft oilseal.
14. Using amallet, driveoutput shaftoutoffront
output housing.
NOTE: Ifitis necessary touse ahand
press toremove outputshaft,position
thrust button LRT-370-11/2 betweenshaft
and press mandrel.
15.Noting itsfitted position, removedogclutch
from output shaft.
16. Noting itsfitted position, removebearing
spacer fromoutput shaft.
17.Taking carenottodamage frontoutput
housing, removeanddiscard outputshaftoil
seal.     
						

							TRANSFERBOX
OVERHAUL 9
18.Using suitable circlippliers, remove and
discard circlipretaining outputshaftbearing.
19.Support frontoutput housing onsuitable blocks
of wood.
20. Using asoft metal drift,drive output shaft
bearing outofhousing; discardbearing.
21.Invert frontoutput housing.
22. Using asoft metal drift,drive differential
bearing trackoutofhousing, discardbearing
track.
23. Remove selective shim.     
						

							TRANSFERBOX
10 OVERHAUL
Rear
output housing
1.Position propeller shaftflange holding tool
LRT-51-003 tooutput shaftflange.
2. Remove anddiscard self-locking nut.
3.Remove steelandfeltwashers, discardfelt
washer.
4. Remove outputshaftflange together with
circlip.
NOTE: Areplacement outputflangewillbe
supplied togetherwithnewoutput shaft
oil seal.
5.Carefully leverspeedometer drivengearand
housing outofrear output housing.
6. Remove anddiscard Oring.
7. Withdraw speedometer drivengearfrom
housing, removeanddiscard oilseal from
housing.    
						

							TRANSFERBOX
OVERHAUL 11
8.Position rearoutput housing onbed ofhand
press.
9. Position thrustbutton LRT-37-11/2 between
end ofoutput shaftandpress mandrel.
10. Press output shaftoutofhousing.
11. Recover spacerandspeedometer drivegear
from output shaft.
12.Using ascrewdriver insertedinslot inrear
output housing, levermudshield outof
housing.
CAUTION: Discardmudshield ifitis
damaged.
13. Taking carenottodamage rearoutput
housing, removeanddiscard outputshaftoil
seal.      
						

							TRANSFERBOX
12 OVERHAUL
14.Using suitable circlippliers, remove and
discard circlipretaining outputshaftbearing.
15.Support rearoutput housing onsuitable blocks
of wood.
16. Using asoft metal drift,drive output shaft
bearing outofhousing; discardbearing. Main
casing
1.Support maincasing onsuitable blocksof
wood.
2. Using asoft metal drift,drive differential rear
bearing trackoutofmain casing; discard
bearing track.
3.Invert maincasing.
4. Using asoft metal drift,drive mainshaft input
gear bearing trackoutofmain casing; discard
bearing track.     
						

							TRANSFERBOX
OVERHAUL 13
Mainshaft
inputgearbearing housing
1.Secure mainshaft inputgearbearing housing in
a soft-jawed vice.
2. Using asoft metal drift,drive inputgear
bearing trackoutofhousing; discardbearing
track.
3. Remove selective shim. Intermediate
gears
1.Secure intermediate gearsinasoft-jawed vice.
2. Using asoft metal drift,drive intermediate shaft
bearing trackoutofgears; discard bearing
track.
3. Remove anddiscard circlip.
4. Repeat aboveprocedure forremaining bearing
track.