Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

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OVERHAUL Mainshaft input gear assembly
NOTE: Defender input gear illustrated.
1.Secure hand pressLRT-99-002in a vice.
2.Assemble collarsLRT-41-003around bearing
to be removed.
3.Position mainshaft in hand press, remove and
discard bearing.
4.Repeat above procedure for remaining
bearing.Differential lock selector
1.Remove and discard self-locking nut retaining
selector lever.
2.Remove washer and selector lever.
3.Withdraw selector finger and shaft from
housing.
4.Remove and discard O ring. 
						

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Differential
1.Secure differential in a soft-jawed vice.
2.Remove staking from bearing retaining nut.
3.Remove nut using toolLRT-41-007;discard
nut.4.Secure hand pressLRT-99-002in a vice.
5.Secure collarsLRT-41-001around rear
bearing.
NOTE: This bearing is adjacent to
threaded end of differential shaft.
6.Position differential in hand press with thrust
button, part of toolLRT-41-001between press
mandrel and differential shaft.
7.Press differential out of bearing.
CAUTION: Take care that differential does
not drop out of bearing.
8.Remove differential from press, discard
bearing. 
						

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OVERHAUL
9.Remove high range gear and bush taking care
not to disturb high/low selector sleeve.
10.Make suitable alignment marks between
high/low selector sleeve and hub.
11.Remove high/low selector sleeve.
12.Using a suitable puller and thrust button, part
of toolLRT-41-001,remove high/low hub and
low range gear. 
						

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13.Secure hand pressLRT-99-002in a vice.
14.Assemble collarsLRT-41-002around front
bearing.
NOTE: This bearing is adjacent to splined
end of differential shaft.
15.Position differential in hand press with thrust
button, part of toolLRT-41-001between press
mandrel and differential shaft.
16.Press differential out of bearing.
CAUTION: Take care that differential does
not drop out of bearing.
17.Remove differential from press, discard
bearing.
18.Secure rear half of differential carrier in a
soft-jawed vice.
19.Make suitable alignment marks between front
and rear halves of differential carrier.
20.Remove 8 bolts securing front half of carrier to
rear; remove carrier.
21.Suitably identify front sun gear to front half of
carrier, remove sun gear.
22.Remove and discard thrust washer.
23.Suitably identify each planet gear to its shaft
and fitted position of each cross shaft to rear
half of carrier.
24.Remove retaining ring.
25.Remove planet gears and cross shafts, remove
and discard dished thrust washers.
26.Suitably identify rear sun gear to rear half of
carrier, remove sun gear.
27.Remove and discard thrust washer. 
						

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OVERHAUL INSPECTING COMPONENTS
1.Clean all components, remove all traces of
silicone sealant using solvent and a plastic
scraper.
2.Clean all traces of Loctite and sealant from
threads of bolts and tapped holes. Ensure
holes are clean and dry.
CAUTION: Do not use a tap to clear
threads in tapped holes.
3.Check all casings and covers for cracks and
damage.
4.Replace any component found to be worn or
damaged.Intermediate gears and shaft
1.Check gear teeth for cracks, chipping and
uneven wear.
2.Check shaft for wear and threads for damage. 
						

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Mainshaft input gear
1.Check gear teeth for cracks, chipping and
uneven wear.
2.Check that cross drillings in shaft are clear.
Defender only
3.Check that ends of dog teeth are not
rounded-off or chipped.High/low cross shaft and housing
1.Check mating surfaces of cross shaft and
drilling in housing for wear.
2.Check core plug in housing for signs of
leakage or corrosion, apply Loctite 326 to
replacement plug.
3.Check high/low selector finger for wear.
4.Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in) 
						

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OVERHAUL Front output housing and differential lock
selector
1.Check bearing track recesses in housing for
damage, rectify or replace housing as
necessary.
2.Check differential lock selector finger shaft and
drilling in housing for wear.
3.Check differential lock selector finger for wear.
4.Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in)
5.Check differential lock selector finger groove
width in differential lock selector shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64
in)
6.Check detent grooves in differential lock
selector shaft for wear.
7.Check differential lock detent ball for flat spots.
8.Check detent spring for distortion.
9.Check differential lock selector fork for cracks
and wear.
10.Check differential lock selector fork finger
width:
Finger width = 7.92 to 7.97 mm (0.311 to 0.313
in )
11.Check differential lock selector fork spring for
distortion and clips for wear and damage.
12.Check spring free length:
Free length = 84.58 mm (3.33 in) 
						

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13.Check dog clutch internal teeth and grooves for
wear and damage.
14.Check dog clutch selector fork groove width:
Groove width = 8.05 to 8.20 mm (0.32 to 0.33
in)
15.Check threads and splines of output shaft for
damage and wear.
16.Check dog clutch teeth on shaft for wear and
damage.Rear output housing
1.Check bearing track recess in housing for
damage, rectify or replace housing as
necessary.
2.Check speedometer drive and driven gears for
damage and wear.
3.Check splines and threads of output shaft for
damage and wear. 
						

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OVERHAUL Main casing
1.Check bearing track recesses in main casing
for damage, rectify or replace casing as
necessary.
2.Remove drain plug, discard sealing washer.
3.Fit new sealing washer, fit drain plug and
tighten to 30 Nm (22 lbf.ft).
4.Remove filler plug, check threads for damage.
5.Fit but do not fully tighten filler plug.
6.Check that locating dowels are fitted in casing
and that blade of front output housing dowel is
positioned as shown.
7.Remove oil temperature switch - if fitted,
remove sealant from threads of switch and
main casing.
8.Apply Hylosil PL32 sealant to threads, fit and
tighten switch.
9.Check high/low detent ball for flat spots.
10.Check detent spring for distortion.Mainshaft input gear bearing housing
1.Check bearing track recess in housing for
damage, rectify or replace housing as
necessary. 
						

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High/low selector fork and shaft
NOTE: There is no need to remove
selector fork from shaft unless fork or
shaft is to be replaced. If fork is removed,
coat threads of set screw with Loctite 290 prior
to assembly.
1.Check detent grooves in shaft for wear.
2.Check high/low selector finger groove width in
shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64
in)
3.Check high/low selector fork for cracks and
wear.
4.Check high/low selector fork finger width:
Finger width = 7.37 to 7.47 mm (0.290 to 0.294
in)