Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

TRANSFER BOX
8
DESCRIPTION AND OPERATION 

TRANSFER BOX
DESCRIPTION AND OPERATION9
REAR OUTPUT HOUSING AND TRANSMISSION
BRAKE COMPONENTS
1.Rear output shaft
2.Rear output housing
3.Bolt - rear output housing
4.Speedometer drive gear
5.Spacer
6.Output shaft bearing
7.Circlip
8.Oil seal
9.Mud shield
10.Output shaft flange
11.Felt washer
12.Steel washer13.Self-locking nut
14.Transmission brake backplate
15.Bolt - transmission brake backplate
16.Transmission brake drum
17.Countersunk screw
18.Speedometer driven gear
19.O ring
20.Speedometer driven...

TRANSFER BOX
10
DESCRIPTION AND OPERATION 

TRANSFER BOX
DESCRIPTION AND OPERATION11
TRANSFER BOX CROSS SECTION
1.Main casing
2.Front output housing
3.Rear output housing
4.Dog clutch
5.Transmission brake
6.Mainshaft input gear
7.Selective shim - input gear bearing pre-load
8.Intermediate gear cluster
9.Intermediate shaft
10.Collapsible spacer11.Differential assembly
12.Selective shim - differential bearing pre-load
13.Low range gear
14.High/low selector sleeve and hub
15.High range gear and bush
16.Differential rear bearing
17.Front output shaft...

TRANSFER BOX
12
DESCRIPTION AND OPERATION Intermediate gears
The intermediate gear cluster is supported by taper
roller bearings located at each end of the cluster and
running on the intermediate shaft which, in turn, is
supported at the front and rear by the main casing.
Intermediate gear bearing pre-load is achieved by
means of a collapsible spacer positioned between
the bearings, the amount of compression applied to
the spacer is by means of a nut on the end of the
intermediate shaft.
Differential...

TRANSFER BOX
DESCRIPTION AND OPERATION13
OPERATION
The gearbox output shaft transmits power to the
mainshaft input gear which is in constant mesh with
one of the intermediate gears. The intermediate
gears are in constant mesh with the high and low
range output gears running on the differential rear
shaft.
Power is transmitted to the output shafts by locking
either the high or low range gears to the differential
rear shaft. This is achieved by means of the high/low
selector fork, sleeve and splined hub....

TRANSFER BOX
OVERHAUL1
TRANSFER BOX DISMANTLING
1.Clean exterior of transfer box.
2.Drain and discard the oil, refit drain plug.
3.Slacken bolt to release transmission brake
adjustment.
4.Remove countersunk screw securing
transmission brake drum, remove drum.
NOTE: 2 screws may be fitted.
5.Make suitable alignment marks between
transmission brake backplate and rear output
housing.
6.Remove 4 bolts securing transmission brake
backplate, remove backplate.
7.Remove Allen screw securing vehicle speed
sensor...

TRANSFER BOX
2
OVERHAUL
10.Release staking from intermediate shaft nut,
remove and discard nut.
11.Remove bolt securing anti-rotation plate,
remove plate.
12.Using a soft metal drift on threaded end of
intermediate shaft, drive shaft out of main
casing.
13.Remove and discard O ring from intermediate
shaft.
14.Remove and discard O ring from main casing.
15.Wrap a suitable length of wire around
intermediate gears and using assistance, lift
gears out of main casing.
16.Remove and discard 2 taper roller...

TRANSFER BOX
OVERHAUL3
NOTE: Discovery cover plate illustrated.
18.Make suitable alignment marks between cover
plate/power take-off cover, mainshaft input
gear bearing housing and main casing.
19.Noting fitted position of stud nut and
harness/speedometer cable clip, remove 5
bolts and stud nut securing cover plate/ power
take-off cover, recover clip.
20.Remove cover plate/power take-off cover.
21.Remove mainshaft input gear bearing housing.
CAUTION: Do not remove mainshaft input
gear bearing track at...