Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

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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 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
fully seated in groove. 
						

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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 end of shaft.
12.Using a mallet, drive output shaft into bearing. 
						

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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 finger shaft and housing.
2.Insert selector finger shaft into housing.
3.Fit selector lever ensuring that relative
positions of lever and finger are as shown.
4.Fit washer and new self-locking nut, tighten nut
to 15 Nm (11 lbf.ft). 
						

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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.
6.Calculate thickness of shim required using the
formula A + B + C = D where:
A = Thickness of installed shim - 3.15 mm
(0.12 in)
B = Recorded end-float
C = Required pre-load - 0.05 mm (0.002 in)
D = Thickness of shim required
7.If an alternative shim is required to establish
correct end-float, proceed as follows:
NOTE: Do not remove mainshaft input
gear bearing housing if bearing pre-load is
correct.
8.Remove 2 bolts, remove mainshaft input gear
bearing housing.
9.Using a soft metal drift, carefully drive input
gear bearing track out of bearing housing,
remove shim.
CAUTION: If bearing track is damaged
during this operation, a new track must be
fitted.
10.Select required shim from the range available.
NOTE: Shims are available from 3.15 to
4.00 mm (0.12 to 0.16 in) thickness rising
in increments of 0.5 mm (0.002 in).
11.Fit selected shim and using a suitable mandrel,
fit input gear bearing track.
12.Fit mainshaft input gear bearing housing and
temporarily secure using 2 M10 x 25 mm bolts
tightened to 25 Nm (18 lbf.ft) . 
						

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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.
9.Restrain flange, tighten nut to 162 Nm (120
lbf.ft).
10.Lubricate a new O ring with recommended oil
and fit to vehicle speed sensor - if fitted.
11.Fit vehicle speed sensor - if fitted.
12.Fit and tighten Allen screw. 
						

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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 pillarLRT-41-014/4into tapped hole in
main casing.
6.Assemble DTILRT-99-006to pillar.
7.Position stylus of DTI to setting block, zero
gauge.
8.Position stylus of gauge on front bearing outer
track, record reading obtained.
9.Position stylus of gauge on opposite side of
bearing track, record reading obtained.
CAUTION: Ensure that bearing track is not
disturbed when carrying out above
operations.
10.Establish average of the 2 readings, record
figure obtained. 
						

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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
bearing outer track
D - Thickness of shim required to give
differential bearing pre-load of 0.05 mm (0.002
in)
18.From resultant figure obtained, select
appropriate thickness shim from the range
available.
NOTE: Shims are available from 2.00 to
3.25 mm (0.08 to 0.13 in) thickness, rising
in increments of 0.05 mm (0.002 in).
19.Retain selected shim and differential front
bearing outer track with front output housing.
20.Carry out assembly of front output housing
-
See Component assembling.
Front output housing
1.Apply Hylosil RTV 102 sealant to mating flange
of front output housing.
2.Fit front output housing ensuring that splines of
output shaft are engaged in differential and that
internal splines of dog clutch are engaged with
teeth of output shaft.
3.Apply Loctite 290 to threads of bolts.
4.Fit bolts noting that longest bolt is inserted
through high/low selector finger housing.
5.Tighten bolts by diagonal selection to 25 Nm
(18 lbf.ft).
6.Fit output flange, new felt and steel washers.
7.Fit a new self-locking nut. 
						

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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 face.
14.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips. 
						

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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 selector lever and
check that differential lock detent ball can be
felt to positively engage and disengage with
grooves in selector shaft; screw detent plug in
or out until setting is correct.
23.Apply Hylomar PL32 sealant to threads of
differential lock warning lamp switch, fit switch.
CAUTION: Do not allow sealant to contact
switch plunger. Do not tighten locknut or
fit differential lock side cover until switch
has been adjusted.