Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

TRANSFER BOX
34
OVERHAUL
8.Slide speedometer drive gear and spacer on to
output shaft.
9.Position rear output housing on bed of hand
press.
10.Locate threaded end of output shaft in bearing.
11.Position thrust buttonLRT-37-11/2between
end of output shaft and press mandrel.
12.Press output shaft into bearing.
13.Fit mud shield with open face of shield towards
oil seal.
CAUTION: Do not fit output shaft flange at
this stage. 

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14.Fit speedometer driven gear into rear output
housing ensuring that gear teeth are engaged
with drive gear.
15.Lubricate a new O ring with recommended oil
and fit to driven gear housing.
16.Fit driven gear housing.
17.Lubricate a new oil seal with recommended oil,
fit seal with lip towards driven gear housing.Front output housing
CAUTION: Do not carry out assembly
operations until differential bearing
pre-load has been determined
- See
differential bearing pre-load.
1.Heat front...

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36
OVERHAUL 5.Lubricate a new output shaft oil seal with
recommended oil.
6.Fit oil seal using toolLRT-41-012.
NOTE: Use end of tool marked FRONT to
fit oil seal.
7.Check that oil seal is just contacting circlip.
8.Position selected shim in front output housing.
9.Fit differential front bearing track using tool
LRT-54-003.
10.Fit bearing spacer to output shaft ensuring that
chamfer on spacer is towards threaded end of
shaft.
11.Fit dog clutch ensuring that flange on clutch is
towards splined...

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High/low cross shaft housing
1.Lubricate cross shaft and new O ring with
recommended oil.
2.Insert cross shaft into housing, position
high/low selector finger on shaft.
3.Fit O ring to shaft, locate end of shaft in
hollow plug.
4.Slide O ring to end of shaft.
5.Align hole in high/low selector finger with
recess in cross shaft.
6.Apply Loctite 290 to threads of setscrew, fit
and tighten screw.Differential lock selector
1.Lubricate new O rings with recommended oil,
fit to selector...

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38
OVERHAUL TRANSFER BOX ASSEMBLING
1.Lubricate all components with recommended
oil.
Mainshaft input gear bearing pre-load
1.Position mainshaft input gear assembly in main
casing.
2.Fit mainshaft input gear bearing housing
ensuring that reference marks are aligned.
3.Fit 2 M10 x 25 mm bolts and tighten to 25 Nm
(18 lbf.ft).
4.Position suitable DTI with stylus of gauge
contacting end of mainshaft, push mainshaft
rearwards and zero gauge.
5.Push mainshaft forwards and note gauge
reading....

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Rear output housing
1.Apply Hylosil RTV 102 sealant to mating flange
of rear output housing.
2.Fit rear output housing to main casing.
NOTE: Dowel located.
3.Apply Loctite 290 to threads of bolts and
shoulder bolt.
4.Fit washers to 2 bolts.
5.Fit bolts and tighten by diagonal selection to 25
Nm (18 lbf.ft).
6.Fit output flange, new felt and steel washers to
output shaft.
7.Fit a new self-locking nut.
8.Position propeller shaft flange holding tool
LRT-51-003to output flange....

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40
OVERHAUL Differential bearing pre-load
1.Position high/low selector shaft and fork to
differential ensuring that fingers of selector fork
are located in high/low selector sleeve.
2.Position high/low selector shaft and differential
in main casing ensuring that splines of rear
output shaft are engaged in differential.
3.Position new differential front bearing outer
track on bearing ensuring that track is seated
squarely.
4.Position setting block, toolLRT-41-014/3on
main casing.
5.Screw...

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11.Position front output housing as shown.
12.Position depth block, toolLRT-41-014/2and
cross-barLRT-41-014/1on front output
housing.
13.Position DTILRT-99-006on cross-bar
LRT-41-014/1.
14.Zero DTI on depth blockLRT-41-014/2.
15.Position DTI to cross-barLRT-41-014/1,
record reading obtained.
16.Remove tools.
17.Using the formula:
3.05 mm (0.120 in) + B - A = D where:
B = Height difference recorded between depth
block and cross bar
A = Average of readings to differential front...

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OVERHAUL
8.Position propeller shaft flange holding tool
LRT-51-003to output flange.
9.Restrain flange, tighten nut to 162 Nm
(120 lbf.ft).10.Compress differential lock selector spring and
fit to selector fork.
11.Locate fingers of selector fork in groove in dog
clutch.
12.Fit differential lock selector shaft ensuring end
of shaft is located in recess in rear of housing.
13.Rotate selector shaft until the two flats for the
retaining clips are at right angles to the cover
plate mating...

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15.Fit differential lock detent ball and spring.
16.Apply Loctite 290 to threads of detent plug.
17.Fit and tighten detent plug then unscrew 2 full
turns.
18.Ensure O ring is correctly located on
differential lock selector housing.
19.Fit differential lock selector assembly ensuring
that selector finger is located in recess in
differential lock selector shaft.
20.Apply Loctite 290 to threads of bolts.
21.Fit bolts and tighten to 25 Nm (18 lbf.ft).
22.Operate differential lock...