Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

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OVERHAUL Differential
1.Check sun and planet gears for wear, cracks
and chipping of teeth.
2.Check cross shafts and recesses in both
halves of differential carrier for damage and
wear.
CAUTION: Ensure planet gears are
retained with their respective shafts.
3.Check retaining ring for distortion.
4.Check splines of differential for wear and
damage.
5.Check teeth of high/low hub for cracks,
chipping and uneven wear.
6.Check selector fork groove width in high/low
hub:
Groove width = 7.5 to 7.6 mm (0.295 to 0.3 in)
7.Check splines and teeth of high/low selector
sleeve for uneven wear, cracks, damage and
chipping.
8.Check teeth of high and low range gears for
cracks, chipping and uneven wear.
9.Check high range gear bush for wear and
damage. 
						

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COMPONENT ASSEMBLING
1.Lubricate all components with recommended
oil.
Differential
1.Lightly oil threads of differential bolts.
2.Secure rear half of differential carrier in a
soft-jawed vice.
3.Fit each planet gear to its respective
cross-shaft, fit new dished thrust washer to
each gear.
4.Fit cross-shafts, planet gears and dished thrust
washers in rear half carrier.
CAUTION: Ensure that cross-shafts are in
their correct fitted position in rear half
carrier. Do not fit sun gear into rear half
carrier at this stage.
5.Fit retaining ring.
6.Fit a 1.05 mm (0.04 in) thick thrust washer to
front half carrier sun gear, position gear in front
half carrier.
NOTE: This is the thinnest of the thrust
washers available.7.Fit front half carrier to rear ensuring that
alignment marks are together.
8.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
9.Insert front output shaft into front half carrier,
check that gears rotate freely.
10.Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
11.Fit transmission brake drum to output flange,
secure drum using 2 nuts.
12.Secure a length of cord around brake drum,
attach one end of cord to a spring balance.
13.Tension cord and note load to turn figure
recorded on spring balance when brake drum
rotates.
NOTE: Used gears should rotate smoothly
whilst new gears will have a notchy feel
as they rotate. 
						

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OVERHAUL 14.Check figure obtained against specified load to
turn figure:
Used gears = 0.45 kg (1.0 lb)
New gears = 1.72 kg (3.8 lb)
15.If load to turn figure is below that specified,
proceed as follows.
16.Remove front output shaft together with brake
drum.
17.Remove 8 bolts securing front half differential
carrier.
18.Remove front half differential carrier.
19.Remove front half carrier sun gear and thrust
washer.
20.Select a thicker thrust washer from the range
available.
NOTE: 5 thicknesses of thrust washers are
available rising in increments of 0.10 mm
(0.004 in) from 1.05 to 1.45 mm (0.04 to
0.06 in).
21.Position selected thrust washer and sun gear
in front half carrier.
22.Fit front half carrier to rear ensuring that
alignment marks are together.
23.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
24.Fit front output shaft and brake drum and
repeat load to turn check.
25.Repeat above procedures as necessary until
load to turn figure is as specified; record final
figure obtained.
26.Remove brake drum from front output shaft,
remove output shaft.
27.Remove bolts securing front half carrier.
28.Remove front half carrier, remove sun gear
and thrust washer.
CAUTION: Keep selected thrust washer
with sun gear.
29.Remove retaining ring.
30.Remove planet gears and cross shafts.
31.Fit a 1.05 mm (0.04 in) thick thrust washer to
rear half carrier sun gear, position gear in rear
half carrier.
32.Fit planet gears, cross shafts and dished thrust
washers in rear half carrier.
CAUTION: Ensure that planet gears are
fitted to their respective cross-shafts and
cross-shafts are fitted in their correct
location in half carrier.
33.Fit retaining ring.
34.Fit front half carrier to rear ensuring that
alignment marks are together.
CAUTION: Do not fit sun gear and thrust
washer into front half carrier.
35.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft). 
						

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36.Invert assembly in vice and then insert rear
output shaft into rear half carrier, check that
gears rotate freely.
37.Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
38.Fit transmission brake drum to output flange,
secure with 2 nuts.
39.Carry out load to turn check using same
method as for front half carrier.
40.When load to turn figure is correct, record final
figure.
41.Upon completion, fit sun gear and selected
thrust washer to front half carrier.
42.Fit front half carrier ensuring that alignment
marks are together.
43.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
44.With differential assembled, fit rear output shaft
and brake drum and check overall load to turn.
This should be approximately equal to total
load to turn figure of both front and rear half
carriers added together:
Used gears = 0.90 kg (2.0 lb)
New gears = 3.44 kg (7.6 lb)
45.Secure rear half carrier in a soft-jawed vice.
46.Fit a new front bearing using toolLRT-41-008. 
						

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OVERHAUL
47.Support front half carrier in a soft-jawed vice.
48.Fit low range gear ensuring that dog teeth on
gear are towards threaded end of shaft.
NOTE: Use a suitable hollow mandrel to fit
gear if it is tight on splines.
49.Fit high/low hub ensuring that alignment mark
made during dismantling is towards threaded
end of shaft.
50.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
51.Fit bush to high range gear ensuring that collar
on bush is on opposite side of gear to the dog
teeth.
52.Fit high range gear and bush ensuring that
collar on bush is towards threaded end of
shaft.
53.Fit a new rear bearing using toolLRT-41-008.
54.Fit a new bearing retainer nut, tighten to 72 Nm
(53 lbf.ft) using toolLRT-41-007.
CAUTION: Do not stake nut at this stage. 
						

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55.Slide high/low selector sleeve and hub away
from low range gear.
56.Using feeler gauges, determine clearance
between low range gear and high/low hub:
Clearance = 0.05 to 0.15 mm (0.002 to 0.006
in)
57.If clearance is not as specified, fit a new low
range gear and high/low hub and re-check.58.Slide high/low selector sleeve and hub away
from high range gear.
59.Using feeler gauges, determine clearance
between high range gear and high/low hub:
Clearance = 0.05 to 0.15 mm (0.002 to 0.006
in)
60.If clearance is not as specified, fit new high
range gear and high/low hub and re-check. 
						

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OVERHAUL
61.Using a round nosed punch, stake collar of nut
into recess in differential shaft.Main casing
1.Fit a new differential rear bearing track using
toolLRT-51-009.
2.Using a straight edge and feeler gauges, check
that bearing track is recessed 1.0 mm (0.04 in)
below outer face of main casing.
3.Using a suitable mandrel, fit a new mainshaft
input gear bearing track.
CAUTION: Ensure bearing tracks are
seated squarely in recesses. 
						

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4.Lubricate a new mainshaft oil seal with
recommended oil.
5.Invert main casing and fit oil seal, lip side
facing inwards, using toolLRT-37-014.Mainshaft input gear bearing housing
1.Ensure bearing track recess in housing is
clean.
2.Position a 3.15 mm (0.12 in) thick shim in
bearing housing.
NOTE: This is the thinnest of the shims
available.
3.Using a suitable mandrel, fit new mainshaft
input gear bearing track.
CAUTION: Ensure bearing track is seated
squarely in recess. 
						

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OVERHAUL Mainshaft input gear assembly
1.Lubricate new bearings with recommended oil.
2.Secure hand pressLRT-99-002in a vice.
3.Position collarsLRT-41-003in hand press.
4.Position new bearing on collars.
NOTE: Smallest diameter of bearing must
be towards collars.
5.Locate end of mainshaft in bearing, press
mainshaft through bearing.
6.Repeat above procedure for remaining
bearing.Intermediate gears.
1.Lubricate new bearings and bearing tracks with
recommended oil.
2.Fit new circlips into intermediate gears.
CAUTION: Ensure that circlips are
correctly seated.
3.Fit new bearing tracks using toolsLRT-41-006
andLRT-99-003.
CAUTION: Ensure bearing tracks are fully
seated against circlips.
4.Retain bearings with intermediate gears. 
						

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Rear output housing
1.Heat rear output housing to 100°C (210°F).
2.Fit new output shaft bearing using tool
LRT-41-011.
3.Allow housing to air cool.
4.Fit new bearing retaining circlip ensuring it is
seated in groove.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 REAR to
fit oil seal.
7.Check that oil seal is just contacting circlip.