Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

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24.Remove 6 bolts securing high/low cross shaft
housing.
25.Remove cross shaft housing.
CAUTION: Do not carry out further
dismantling of cross shaft housing at this
stage.
26.Slacken locknut and remove differential lock
warning lamp switch from front output housing.
27.Clean sealant from threads of switch and
output housing.
28.Noting fitted position of longest bolt, remove 8
bolts securing front output housing to main
casing.
29.Remove front output housing.
NOTE: Dowel located.
CAUTION: Do not carry out further
dismantling of front output housing at this
stage. 
						

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30.Noting their fitted position, remove shoulder
bolt, 5 bolts and 2 washers securing rear
output housing to main casing.
31.Remove rear output housing.
NOTE: Dowel located.
CAUTION: Do not carry out further
dismantling of rear output housing at this
stage.
32.Remove plug securing high/low selector shaft
detent spring and ball.
33.Remove detent spring.
34.Remove ball using a stick magnet.
CAUTION: Suitably identify plug, detent
spring and ball to their fitted positions, do
not interchange with differential lock
selector shaft detent components.
If fitted
35.Remove 4 bolts securing interlock solenoid
cover, remove cover and Belleville washer.
36.Remove interlock solenoid.
37.Remove neutral warning lamp switch and
washer. 
						

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All transfer boxes
38.Withdraw differential assembly together with
high/low selector shaft and fork.COMPONENT DISMANTLING
High/low cross shaft housing
1.Remove setscrew securing high/low selector
finger to cross shaft.
2.Withdraw cross shaft from housing, recover
high/low selector finger.
3.Remove and discard O ring. 
						

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Front output housing
1.Remove 7 bolts securing differential lock
selector side cover, remove cover.
2.Remove 3 bolts securing differential lock
selector housing, remove housing and selector
as an assembly.
3.Remove and discard O ring from selector
housing.
4.Remove plug securing differential lock detent
spring and ball.
5.Remove detent spring.
6.Remove ball using a stick magnet.
CAUTION: Suitably identify plug, detent
spring and ball to their fitted positions, do
not interchange with high/low selector
shaft detent components.
7.Compress differential lock selector fork spring
and remove retaining clip from each end of
spring.
8.Withdraw differential lock selector shaft from
front output housing, recover spring.
9.Remove differential lock selector fork. 
						

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10.Position propeller shaft flange holding tool
LRT-51-003to output shaft flange.
11.Remove and discard self-locking nut.
12.Remove steel and felt washers, discard felt
washer.
13.Remove output shaft flange together with mud
shield.
NOTE: A replacement output flange will be
supplied with new mud shield and output
shaft oil seal.
14.Using a mallet, drive output shaft out of front
output housing.
NOTE: If it is necessary to use a hand
press to remove output shaft, position
thrust button LRT-370-11/2 between shaft
and press mandrel.
15.Noting its fitted position, remove dog clutch
from output shaft.
16.Noting its fitted position, remove bearing
spacer from output shaft.
17.Taking care not to damage front output
housing, remove and discard output shaft oil
seal. 
						

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18.Using suitable circlip pliers, remove and
discard circlip retaining output shaft bearing.
19.Support front output housing on suitable blocks
of wood.
20.Using a soft metal drift, drive output shaft
bearing out of housing; discard bearing.
21.Invert front output housing.
22.Using a soft metal drift, drive differential
bearing track out of housing, discard bearing
track.
23.Remove selective shim. 
						

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OVERHAUL Rear output housing
1.Position propeller shaft flange holding tool
LRT-51-003to output shaft flange.
2.Remove and discard self-locking nut.
3.Remove steel and felt washers, discard felt
washer.
4.Remove output shaft flange together with
circlip.
NOTE: A replacement output flange will be
supplied together with new output shaft
oil seal.
5.Carefully lever speedometer driven gear and
housing out of rear output housing.
6.Remove and discard O ring.
7.Withdraw speedometer driven gear from
housing, remove and discard oil seal from
housing. 
						

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8.Position rear output housing on bed of hand
press.
9.Position thrust buttonLRT-37-11/2between
end of output shaft and press mandrel.
10.Press output shaft out of housing.
11.Recover spacer and speedometer drive gear
from output shaft.
12.Using a screwdriver inserted in slot in rear
output housing, lever mud shield out of
housing.
CAUTION: Discard mud shield if it is
damaged.
13.Taking care not to damage rear output
housing, remove and discard output shaft oil
seal. 
						

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14.Using suitable circlip pliers, remove and
discard circlip retaining output shaft bearing.
15.Support rear output housing on suitable blocks
of wood.
16.Using a soft metal drift, drive output shaft
bearing out of housing; discard bearing.Main casing
1.Support main casing on suitable blocks of
wood.
2.Using a soft metal drift, drive differential rear
bearing track out of main casing; discard
bearing track.
3.Invert main casing.
4.Using a soft metal drift, drive mainshaft input
gear bearing track out of main casing; discard
bearing track. 
						

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Mainshaft input gear bearing housing
1.Secure mainshaft input gear bearing housing in
a soft-jawed vice.
2.Using a soft metal drift, drive input gear
bearing track out of housing; discard bearing
track.
3.Remove selective shim.Intermediate gears
1.Secure intermediate gears in a soft-jawed vice.
2.Using a soft metal drift, drive intermediate shaft
bearing track out of gears; discard bearing
track.
3.Remove and discard circlip.
4.Repeat above procedure for remaining bearing
track.