Land Rover Lt230q Overhaul Rover Manual
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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 anddifferential gears. CAUTION: Donot remove wireatthis stage.
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.
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. Donot stake nutatthis stage. 12.Setintermediate gearbearing pre-load-See Intermediate gearbearing pre-load. Intermediate gearbearing pre-load 1. Select neutral. 2. Screw asuitable boltintotapped holeinend of tool LRT-41-005. 3.Insert toolLRT-41-005 inend ofmainshaft. 4. Using asuitable torquemeterontool LRT-41-005, checkandrecord torquetoturn mainshaft inputgears. 5. Tighten theintermediate shaftnutinsmall stages checking thetorque toturn thegears until themainshaft inputgeartorque toturn figure recorded inoperation 4has increased by 1.25 Nm(10lbf.in ). CAUTION: Takegreat carenotto overtighten nutasthis willcause excessive bearingpre-load. Iftorque to turn figure isinadvertently exceeded,anew collapsible spacermustbefitted.
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 face of cover plate/power take-offcover,position plate/cover onbearing housing ensuring that reference marksarealigned. 10. Position cliptostud nut. 11. Apply Loctite 290tothreads ofbolts andstud nut. 12. Fit5bolts andstud nutand tighten bydiagonal selection to25 Nm (18lbf.ft). NOTE: Theseboltsarethreaded tohead. Bottom cover 1. Apply Hylosil RTV102sealant tomating face of bottom cover. 2.Fitbottom cover. 3. Apply Loctite 290tothreads ofbottom cover securing bolts 4. Fitbolts inpositions shownandtighten by diagonal selection to25 Nm (18lbf.ft.
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 washer,fit bolts andtighten to10 Nm (8lbf.ft).
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 testlamp. 6. Apply sealant fromkittomating faceof differential lockside cover. 7. Fitside cover, fitbolts andtighten to25 Nm (18 lbf.ft).
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.
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 ....... 0.63to0.64 in Differential lockselector forkfinger width 7.92to7.97 mm ......... 0.311to0.313 in Differential lockselector springfreelength 84.58mm ........ 3.33in Dog clutch selector forkgroove width 8.05to8.20 mm ............ 0.32to0.33 in Differential frontandrear halfcarrier gearsload to turn: Used gears 0.45kg ............................... 1.0 lb New gears 1.72kg ................................ 3.8 lb Thrust washer thicknesses available 1.05to1.45 mm ............. 0.04to0.06 in In increments of: 0.10mm ........................... 0.004in Total loadtoturn -both sungears fitted: Used gears 0.90kg ............................... 2.0 lb New gears 3.44kg ................................ 7.6 lb Low range geartohigh range hubclearance 0.05to0.15 mm ...... 0.002to0.006 in High range geartohigh/low hubclearance 0.05to0.15 mm ........ 0.002to0.006 in Mainshaft inputgearbearing pre-load 0.05mm ............ 0.002in Mainshaft inputbearing shimthicknesses available 3.15to4.00 mm .................................. 0.12to0.16 in In increments of: 0.05mm ........................... 0.002in Differential bearingpre-load 0.05 ................... 0.002in Differential bearingshimthicknesses available 2.00to3.25 mm ..... 0.08to0.13 in In increments of: 0.05mm ........................... 0.002in Intermediate gearbearing pre-load - An increase onmainshaft inputgear initial torque toturn of 1.25Nm ........................ 10 lbf.in
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 selectorhousing bolts 25Nm ................. 18 lbf.ft * Intermediate shaftretaining platebolt 25Nm ........... 18 lbf.ft * Bottom coverbolts 25Nm ......................... 18 lbf.ft * Bearing housing coverplateboltsandstud nut 25Nm . .. 18lbf.ft Transmission brakebackplate bolts 70Nm ............. 52 lbf.ft Interlock solenoidcoverbolts-if fitted 10Nm ............ 8lbf.ft * Apply Loctite 290tothreads
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 Outputshaftbearing replacer LRT-41-012 Outputshaftoilseal replacer LRT-41-014/1 Cross-bar LRT-41-014/2 Depthblock LRT-41-014/3 Settingblock LRT-41-014/4 Pillar LRT-51-003 Propellershaftflange holding tool LRT-51-009 Differentialrearbearing trackreplacer LRT-54-003 Differentialfrontbearing trackreplacer LRT-99-002 Handpress LRT-99-003 Driverhandle LRT-99-006 Dialtestindicator (DTI)