Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual
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TRANSFERBOX DESCRIPTION ANDOPERATION 9 REAR OUTPUT HOUSING ANDTRANSMISSION BRAKE COMPONENTS 1. Rear output shaft 2. Gasket * 3. Rear output housing 4. Bolt -rear output housing 5. Speedometer drivegear 6. Spacer 7. Output shaftbearing 8. Circlip 9. Oil seal 10. Mud shield 11. Output shaftflange 12. Feltwasher 13. Steel washer 14. Self-locking nut 15. Transmission brakebackplate 16. Bolt -transmission brakebackplate 17. Transmission brakedrum 18. Countersunk screw 19. Speedometer drivengear 20. Oring 21. Speedometer drivengearhousing 22. Seal 23. Oring ** 24. Vehicle speedsensor ** 25. Allen screw ** * U p to serial no.288709E ** Iffitted
TRANSFERBOX DESCRIPTION ANDOPERATION 11 TRANSFER BOXCROSS SECTION 1. Main casing 2. Front output housing 3. Rear output housing 4. Dog clutch 5. Transmission brake 6. Mainshaft inputgear 7. Selective shim-input gearbearing pre-load 8. Intermediate gearcluster 9. Intermediate shaft 10. Collapsible spacer 11. Differential assembly 12. Selective shim-differential bearingpre-load 13. Low range gear 14. High/low selectorsleeveandhub 15. High range gearandbush 16. Differential rearbearing 17. Front output shaft 18. Differential lockselector shaft 19. Selector fork 20. Rear output shaft DESCRIPTION IntroductionThe LT230T transferboxismounted atthe rear of the main gearbox andtransmits drivetothe front and rear axles viathe propeller shafts. ConstructionThe transfer boxcomprises threemainassemblies, the main casing, frontoutput housing andrear output housing. The main casing carries themainshaft inputgear, the intermediate gearsandthedifferential together with thehigh/low rangegears, selector shaftand fork.The front output housing carriesthefront output shaft andflange, high/low crossshaft, housing and selector andthedifferential lockselector shaftand fork. Adog clutch onthe front output shaftis operated bythe differential lockselector forkto engage/disengage thedifferential lock. The rear output housing carriestherear output shaft and flange andthespeedometer driveanddriven gears. Amechanically operatedtransmission brake is attached tothe housing, thebrake drumbeing attached tothe output flange. All housings andcover plates aresealed tothe the main casing bygaskets orsealant; mudandwater ingress beingprevented bymud shields and throwers locatedateach endofthe output housings and onthe drive flanges. Mainshaft inputgear The gearbox outputshaftissplined intothe mainshaft inputgearwhich issupported bytaper roller bearings. Input gearbearing pre-load isachieved bythe use of a selective shimlocated inthe bearing housing. An additional powertake-off gearislocated atthe rear of the input gearforcertain applications. Intermediate gears The intermediate gearcluster issupported bytaper roller bearings locatedateach endofthe cluster and running onthe intermediate shaftwhich, inturn, is supported atthe front andrear bythe main casing. Intermediate gearbearing pre-load isachieved by means ofacollapsible spacerpositioned between the bearings, theamount ofcompression appliedto the spacer isby means ofanut onthe end ofthe intermediate shaft.
TRANSFERBOX 12 DESCRIPTION ANDOPERATION Differential assembly The differential assemblyissupported atthe front and rear bytaper rollerbearings, thebearing outer tracks beinglocated inthe front andrear output housings. Bearingpre-load isachieved bymeans of a selective shimlocated inthe front output housing. The differential rearshaft carries thelow range gear, high/low selectorsleeveandhub, highrange gear and bush andthedifferential rearbearing; these components beingsecured tothe shaft byaspecial nut. The differential assemblycomprises frontandrear half carriers withintegral shaftsandsunand planet gears mounted oncross shafts withinthehalf carriers. Dished,non-selective thrustwashers control theengagement ofthe planet gearswiththe sun gears whilstselective thrustwashers areused to control theengagement ofthe sun gears andload to turn ofthe differential. Thedifferential carrier halves arebolted together, aretaining ringproviding positive location ofthe cross shafts. The high/low selectorshaftandforkarelocated at the side ofthe differential, movementofthe shaft, fork and selector sleevebeingcontrolled bythe high/low selectorfinger.Aspring loaded detentball fitted inthe main casing, locatesingrooves inthe shaft.For certain markets, aneutral warning lampswitch operated bythe high/low selectorshaftandan interlock solenoid arefitted inthe main casing. Front output housing assembly The front output shaftissupported inthe front output housing byasingle bearing andissplined intothe differential frontshaft. The high/low crossshaftislocated inahousing bolted tothe topofthe output housing andis connected tothe high/low selectorfingerwhich locates inaslot inthe selector shaft. The differential lockselector housing isalso bolted to the topofthe front output housing, theselector finger passes through thehousing, locatinginaslot in the differential lockselector shaft.Thedifferential lock selector shaftpasses through theselector fork which islocated beneath aplate bolted tothe side of the output housing. Aspring loaded detentballfitted in the output housing locatesingrooves inthe shaft. A differential lockwarning lampswitch, operated by movement ofthe selector forkand shaft isscrewed into thetopofthe output housing. Range RoverClassic only-For certain markets, a neutral warning lampswitch operated bythe high/low crossshaftisscrewed intotheside ofthe housing.Rear output housing assembly The rear output shaftissupported inthe rear output housing byasingle bearing andissplined intothe differential rearshaft. Theoutput shaftalsocarries the speedometer drivegearwhich meshes withthe driven gearlocated inthe rear output housing. LubricationLubrication isby splash, oilfiller/level anddrain plugs being located inthe main casing. Anoil temperature switchisalso fitted forcertain applications.
TRANSFERBOX DESCRIPTION ANDOPERATION 13 OPERATION The gearbox outputshafttransmits powertothe mainshaft inputgearwhich isin constant meshwith one ofthe intermediate gears.Theintermediate gears areinconstant meshwiththehigh andlow range output gearsrunning onthe differential rear shaft.Power istransmitted tothe output shaftsbylocking either thehigh orlow range gearstothe differential rear shaft. Thisisachieved bymeans ofthe high/low selector fork,sleeve andsplined hub. The differential lock,when applied, prevents all available powerbeingtransmitted tothe road wheels offering leastresistance andisespecially usefulfor off-road conditions. Whenselected, theselector fork engages thedog clutch onthe differential shaft with agear onthe front output shaft;thislocks the differential andprovides fixeddrive thereby transmitting equalpower toboth output shafts.
TRANSFERBOX OVERHAUL 1 TRANSFER BOXDISMANTLING 1. Clean exterior oftransfer box. 2. Drain anddiscard theoil,refit drain plug. 3.Slacken bolttorelease transmission brake adjustment. 4. Remove countersunk screwsecuring transmission brakedrum, remove drum. NOTE:2screws maybefitted. 5.Make suitable alignment marksbetween transmission brakebackplate andrear output housing. 6. Remove 4bolts securing transmission brake backplate, removebackplate. 7.Remove Allenscrew securing vehiclespeed sensor -if fitted. 8. Remove vehiclespeedsensor, remove and discard Oring -if fitted. 9. Remove 6bolts securing bottomcover,remove cover. 10. Up toserial no.288709E:Remove and discard gasket.
TRANSFERBOX 2 OVERHAUL 11.Release stakingfromintermediate shaftnut, remove anddiscard nut. 12. Remove boltsecuring anti-rotation plate, remove plate. 13.Using asoft metal driftonthreaded endof intermediate shaft,driveshaftoutofmain casing. 14. Remove anddiscard Oring from intermediate shaft. 15. Remove anddiscard Oring from main casing. 16.Wrap asuitable lengthofwire around intermediate gearsandusing assistance, lift gears outofmain casing. 17.Remove anddiscard 2taper rollerbearings from intermediate gears. 18. Remove anddiscard collapsible spacerfrom intermediate gears. CAUTION:Donot remove bearing tracks at this stage.
TRANSFERBOX OVERHAUL 3 NOTE:Discovery coverplateillustrated. 19.Make suitable alignment marksbetween cover plate/power take-offcover,mainshaft input gear bearing housing andmain casing 20. Noting fittedposition ofstud nutand harness/speedometer cableclip,remove 5 bolts andstud nutsecuring coverplate/power take-off cover,recover clip. 21. Remove coverplate/power take-offcover. 22. Up toserial no.288709E:Remove anddiscard gasket. 23. Remove oilfeed plate -if fitted, remove and discard Oring. 24. Remove 2countersunk screws-if fitted securing mainshaft inputgearbearing housing. 25. Up toserial no.288709E:Remove mainshaft input gearbearing housing, removeand discard gasket. CAUTION: Donot remove mainshaft input gear bearing trackatthis stage. 26.From serial no.288709E:Remove mainshaft input gearbearing housing. CAUTION: Donot remove mainshaft input gear bearing trackatthis stage.