Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

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OVERHAUL
24.Apply Hylosil RTV 102 sealant to mating flange
of high/low selector housing.
25.Fit housing ensuring that high/low selector
finger is located in recess in high/low selector
shaft.
26.Fit 6 bolts and tighten to 25 Nm (18 lbf.ft).Intermediate gears1.Insert a new collapsible spacer into
intermediate gears, fit bearings into bearing
tracks.
2.Wrap a suitable length of wire around
intermediate gears and using assistance, lower
gears into main casing ensuring that they are
meshing...

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OVERHAUL45
3.Lubricate new O rings with recommended oil
and fit to intermediate shaft and main casing.
4.Raise intermediate gears until dummy shaft
LRT-41-004can be inserted from front output
housing side of main casing.
5.Fit intermediate shaft, drift shaft into position
whilst at the same time expelling dummy shaft
LRT-41-004 .
CAUTION: Ensure O ring is not displaced
from main casing. 

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OVERHAUL 6.Remove wire from around intermediate gears.
7.Rotate intermediate shaft until retaining plate
can be located on flat on shaft.
8.Apply Loctite 290 to threads of retaining plate
bolt.
9.Fit bolt and tighten to 25 Nm (18 lbf.ft).
10.Fit a new intermediate shaft nut.
11.Tighten intermediate shaft nut in small stages
until all end-float is just removed from
intermediate gears.
CAUTION: Check end-float of intermediate
gears between each stage, do not
continue tightening nut after...

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OVERHAUL47
6.When torque to turn figure - intermediate gear
bearing pre-load is correct, stake flange of
intermediate shaft nut into recess in
intermediate shaft.
7.Remove toolLRT-41-005.
NOTE: Discovery cover plate illustrated.
8.Remove 2 bolts used to temporarily secure
mainshaft input gear bearing housing, remove
housing. Apply Hylosil 2000 sealant to main
casing mating face of bearing housing, position
housing on main casing ensuring reference
marks are aligned.
9.Apply Hylosil RTV 102...

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OVERHAUL High/low selector shaft detent
1.Fit detent ball and spring.
2.Apply Loctite 290 to threads of detent plug.
3.Fit and tighten plug then unscrew 2 full turns.
4.Operate high/low selector lever and check that
detent ball can be felt to positively engage and
disengage with grooves in selector shaft; screw
plug in or out until setting is correct.Interlock solenoid - if fitted
1.Position solenoid in main casing.
2.Apply Hylosil RTV 102 to mating face of
solenoid cover.
3.Fit solenoid...

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Neutral warning lamp switch - if fitted
1.Apply Hylosil PL 32 sealant to threads of
switch.
2.Fit washer, fit and tighten switch.Differential lock warning lamp switch - adjust
1.Move differential lock selector fork to
differential locked position.
2.Connect a 12V test lamp and battery to
differential lock switch.
3.Screw switch in until test lamp is illuminated
then screw switch in a further 1/2 turn; tighten
locknut.
4.Disengage differential lock, check that test
lamp is...

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OVERHAUL Transmission brake
1.Apply Hylosil RTV 102 sealant to mating face
of rear output housing.
2.Position brake backplate on rear output
housing ensuring that alignment marks are
together.
3.Fit 4 bolts and tighten to 70 Nm (52 lbf.ft).
4.Fit transmission brake drum, fit countersunk
screw and tighten. 

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DATA, TORQUE & TOOLS1
DATA
High/low selector finger width 15.90 to 15.95 mm..................0.625 to 0.627 in
High/low selector fork finger width 7.37 to 7.47 mm...............0.290 to 0.294 in
High/low selector shaft groove width 16.0 to 16.1 mm.............0.63 to 0.64 in
High/low selector hub groove width 7.5 to 7.6 mm..............0.295 to 0.30 in
Differential lock selector finger width 15.90 to 15.95 mm.............0.625 to 0.627 in
Differential lock selector shaft groove width 16.0 to...

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DATA, TORQUE & TOOLS TORQUE FIGURES
Drain plug 30 Nm................................. 22lbf.ft
Differential carrier bolts 60 Nm....................... 44lbf.ft
Differential bearing nut 72 Nm....................... 53lbf.ft
Differential lock selector lever nut 15 Nm............... 11lbf.ft
* Front and rear output housing bolts 25 Nm............ 18lbf.ft
Output flange nuts 162 Nm........................... 120lbf.ft
* Differential lock selector housing bolts 25 Nm.......... 18lbf.ft
High/low...

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DATA, TORQUE & TOOLS3
SERVICE TOOLS
LRT-37-11/2 Thrust button
LRT-37-014 Mainshaft oil seal replacer
LRT-41-001 Collars - differential rear bearing
LRT-41-001 Thrust button
LRT-41-002 Collars - differential front bearing
LRT-41-003 Mainshaft input gear bearing remover/replacer
LRT-41-004 Intermediate gear dummy shaft
LRT-41-005 Input gear mandrel
LRT-41-006 Intermediate gear bearing track replacer
LRT-41-007 Differential bearing nut remover/replacer
LRT-41-008 Differential bearing replacer...