Land Rover Lt230q Transfer Gearbox Overhaul 2nd Edition Rover Manual

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44
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 with input and differential gears.
CAUTION: Do not remove wire at this
stage. 
						

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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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46
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 end-float is
removed. Do not stake nut at this stage.
12.Set intermediate gear bearing pre-load
- See
Intermediate gear bearing pre-load.
Intermediate gear bearing pre-load
1.Select neutral.
2.Screw a suitable bolt into tapped hole in end of
toolLRT-41-005.
3.Insert toolLRT-41-005in end of mainshaft.
4.Using a suitable torque meter on tool
LRT-41-005,check and record torque to turn
mainshaft input gears.
5.Tighten the intermediate shaft nut in small
stages checking the torque to turn the gears
until the mainshaft input gear torque to turn
figure recorded in operation 4 has increased by
1.25 Nm (10 lbf.in ).
CAUTION: Take great care not to
overtighten nut as this will cause
excessive bearing pre-load. If torque to
turn figure is inadvertently exceeded, a new
collapsible spacer must be fitted. 
						

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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 sealant to mating face
of cover plate/power take-off cover, position
plate/cover on bearing housing ensuring that
reference marks are aligned.
10.Position clip to stud nut.
11.Apply Loctite 290 to threads of bolts and stud
nut.
12.Fit 5 bolts and stud nut and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
NOTE: These bolts are threaded to head.Bottom cover
1.Apply Hylosil RTV 102 sealant to mating face
of bottom cover.
2.Fit bottom cover.
3.Apply Loctite 290 to threads of bottom cover
securing bolts
4.Fit bolts in positions shown and tighten by
diagonal selection to 25 Nm (18 lbf.ft. 
						

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48
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 cover and Belleville washer, fit
bolts and tighten to 10 Nm (8 lbf.ft). 
						

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OVERHAUL49
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 extinguished.
5.Remove test lamp.
6.Apply sealant from kit to mating face of
differential lock side cover.
7.Fit side cover, fit bolts and tighten to 25 Nm (18
lbf.ft). 
						

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50
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 16.1 mm.......0.63 to 0.64 in
Differential lock selector fork finger width 7.92 to 7.97 mm.........0.311 to 0.313 in
Differential lock selector spring free length 84.58 mm........3.33 in
Dog clutch selector fork groove width 8.05 to 8.20 mm............0.32 to 0.33 in
Differential front and rear half carrier gears load
to turn:
Used gears 0.45 kg............................... 1.0lb
New gears 1.72 kg................................ 3.8lb
Thrust washer thicknesses available 1.05 to 1.45 mm.............0.04 to 0.06 in
In increments of: 0.10 mm...........................0.004 in
Total load to turn - both sun gears fitted:
Used gears 0.90 kg............................... 2.0lb
New gears 3.44 kg................................ 7.6lb
Low range gear to high range hub clearance 0.05 to 0.15 mm......0.002 to 0.006 in
High range gear to high/low hub clearance 0.05 to 0.15 mm........0.002 to 0.006 in
Mainshaft input gear bearing pre-load 0.05 mm............0.002 in
Mainshaft input bearing shim thicknesses
available 3.15 to 4.00 mm..................................0.12 to 0.16 in
In increments of: 0.05 mm...........................0.002 in
Differential bearing pre-load 0.05...................0.002 in
Differential bearing shim thicknesses available 2.00 to 3.25 mm.....0.08 to 0.13 in
In increments of: 0.05 mm...........................0.002 in
Intermediate gear bearing pre-load -
An increase on mainshaft input gear
initial torque to turn of 1.25 Nm........................ 10lbf.in 
						

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2
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 selector housing bolts 25 Nm................. 18lbf.ft
* Intermediate shaft retaining plate bolt 25 Nm........... 18lbf.ft
* Bottom cover bolts 25 Nm......................... 18lbf.ft
* Bearing housing cover plate bolts and stud nut 25 Nm. . . 18 lbf.ft
Transmission brake backplate bolts 70 Nm............. 52lbf.ft
Interlock solenoid cover bolts - if fitted 10 Nm............ 8lbf.ft
* Apply Loctite 290 to threads 
						

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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
LRT-41-011 Output shaft bearing replacer
LRT-41-012 Output shaft oil seal replacer
LRT-41-014/1 Cross-bar
LRT-41-014/2 Depth block
LRT-41-014/3 Setting block
LRT-41-014/4 Pillar
LRT-51-003 Propeller shaft flange holding tool
LRT-51-009 Differential rear bearing track replacer
LRT-54-003 Differential front bearing track replacer
LRT-99-002 Hand press
LRT-99-003 Driver handle
LRT-99-006 Dial test indicator (DTI)