Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual

TRANSFERBOX
44 OVERHAUL
10.Compress differential lockselector springand
fit to selector fork.
11. Locate fingersofselector forkingroove indog
clutch.
12. Fitdifferential lockselector shaftensuring end
of shaft islocated inrecess inrear ofhousing.
13. Rotate selector shaftuntilthetwo flats forthe
retaining clipsareatright angles tothe cover
plate mating face.
14.Compress selectorspringandfitretaining clips
at each endofspring.
CAUTION: Ensureendsofspring arefully
seated inrecess inclips.
15....

TRANSFERBOX
OVERHAUL 45
18.Ensure Oring iscorrectly locatedon
differential lockselector housing.
19. Fitdifferential lockselector assembly ensuring
that selector fingerislocated inrecess in
differential lockselector shaft.
20. Apply Loctite 290tothreads ofbolts.
21. Fitbolts andtighten to25 Nm (18lbf.ft).
22. Operate differential lockselector leverand
check thatdifferential lockdetent ballcan be
felt topositively engageanddisengage with
grooves inselector shaft;screw detent plugin
or out until setting...

TRANSFERBOX
46 OVERHAUL
Intermediate
gears
1.Insert anew collapsible spacerinto
intermediate gears,fitbearings intobearing
tracks.
2. Wrap asuitable lengthofwire around
intermediate gearsandusing assistance, lower
gears intomain casing ensuring thatthey are
meshing withinput anddifferential gears.
CAUTION: Donot remove wireatthis
stage.
3. Lubricate newOrings withrecommended oil
and fitto intermediate shaftandmain casing.    

TRANSFERBOX
OVERHAUL 47
4.Raise intermediate gearsuntildummy shaft
LRT-41-004 canbeinserted fromfrontoutput
housing sideofmain casing.
5. Fitintermediate shaft,driftshaft intoposition
whilst atthe same timeexpelling dummyshaft
LRT-41-004 .
CAUTION:EnsureOring isnot displaced
from main casing.
6.Remove wirefrom around intermediate gears.
7.Rotate intermediate shaftuntilretaining plate
can belocated onflat onshaft.
8. Apply Loctite 290tothreads ofretaining plate
bolt.
9. Fitbolt and tighten to25 Nm...

TRANSFERBOX
48 OVERHAUL
Intermediate
gearbearing pre-load
1. Select neutral.
2. Screw asuitable boltintotapped holeinend of
tool LRT-41-005.
3.Insert toolLRT-41-005 inend ofmainshaft.
4. Using asuitable torquemeterontool
LRT-41-005, checkandrecord torquetoturn
mainshaft inputgears.
5. Tighten theintermediate shaftnutinsmall
stages checking thetorque toturn theinput
gears untilthemainshaft inputgeartorque to
turn figure recorded inoperation 4has
increased by1.25 Nm(10lbf.in).
CAUTION: Takegreat carenotto...

TRANSFERBOX
OVERHAUL 49
Alltransfer boxes
13.Apply Hylosil RTV102sealant orposition new,
dry gasket tomating faceofcover plate/power
take-off cover.Position plate/cover onbearing
housing ensuring thatreference marksare
aligned.
14. Position cliptostud nut.
15. Apply Loctite 290tothreads ofbolts andstud
nut.
16. Fit5bolts andstud nutand tighten bydiagonal
selection to25 Nm (18lbf.ft).
NOTE: Theseboltsarethreaded tohead.
Bottom cover
1.
Up toserial no.288709E:Position newbottom
cover gasket, dryonmain...

TRANSFERBOX
50 OVERHAUL
High/low
selectorshaftdetent
1.Fitdetent balland spring.
2. Apply Loctite 290tothreads ofdetent plug.
3. Fitand tighten plugthen unscrew 2full turns.
4. Operate high/low selectorleverandcheck that
detent ballcan befelt topositively engageand
disengage withgrooves inselector shaft;screw
plug inor out until setting iscorrect. Interlock
solenoid-if fitted
1. Position interlock solenoid inmain casing.
2. Apply Hylosil RTV102tomating faceof
solenoid cover.
3. Fitsolenoid...

TRANSFERBOX
OVERHAUL 51
Neutral
warning lampswitch -if fitted -not
Range RoverClassic
1.Apply Hylosil PL32sealant tothreads of
switch.
2. Fitwasher, fitand tighten switch. Differential
lockwarning lampswitch -adjust
1. Move differential lockselector forkto
differential lockedposition.
2. Connect a12V testlamp andbattery to
differential lockswitch.
3. Screw switchinuntil testlamp isilluminated
then screw switch inafurther 1/2turn; tighten
locknut.
4. Disengage differentiallock,check thattest
lamp...

TRANSFERBOX
52 OVERHAUL
Transmission
brake
1. Apply Hylosil RTV102sealant tomating face
of rear output housing.
2.Position brakebackplate onrear output
housing ensuring thatalignment marksare
together.
3. Fit4bolts andtighten to70 Nm (52lbf.ft).
4. Fittransmission brakedrum, fitcountersunk
screw andtighten.
NOTE: Earlytransfer boxes-2 screws are
fitted.  

TRANSFERBOX
DATA, TORQUE &TOOLS 1
DATA High/low
selectorfingerwidth 15.90to15.95 mm
.................. 0.625to0.627 in
High/low selectorforkfinger width 7.37to7.47 mm
............... 0.290to0.294 in
High/low selectorshaftgroove width 16.0to16.1 mm
............. 0.63to0.64 in
High/low selectorhubgroove width 7.5to7.6 mm
.............. 0.295to0.30 in
Differential lockselector fingerwidth 15.90to15.95 mm
............. 0.625to0.627 in
Differential lockselector shaftgroove width 16.0to16.1 mm
..........