Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual

							TRANSFERBOX
4 OVERHAUL
27.Remove mainshaft inputgeartogether with
taper rollerbearings.
NOTE: Inputgearfitted toDefender
transfer boxeshasanadditional dogtooth
gear -see inset onillustration.
28. Remove anddiscard mainshaft oilseal from
main casing.
CAUTION: Donot remove mainshaft input
gear bearing trackatthis stage.
29.Remove 6bolts securing high/lowcrossshaft
housing.
30. Remove crossshafthousing.
31.
Up toserial no.288709E:Remove and
discard gasket.
CAUTION: Donot carry outfurther
dismantling ofcross shafthousing atthis
stage.    
						

							TRANSFERBOX
OVERHAUL 5
32.Slacken locknutandremove differential lock
warning lampswitch fromfrontoutput housing.
33.Noting fittedposition oflongest bolt,remove 8
bolts securing frontoutput housing tomain
casing.
34. Remove frontoutput housing.
NOTE: Dowellocated.
35.Uptoserial no.288709E:Remove and
discard gasket.
CAUTION: Donot carry outfurther
dismantling offront output housing atthis
stage.
36. Noting theirfitted position, removeshoulder
bolt, 5bolts and2washers securing rear
output housing tomain casing.
37. Remove rearoutput housing.
NOTE: Dowellocated.
38.Uptoserial no.288709E:Remove and
discard gasket.
CAUTION: Donot carry outfurther
dismantling ofrear output housing atthis
stage.     
						

							TRANSFERBOX
6 OVERHAUL
39.Remove plugsecuring high/lowselectorshaft
detent springandball.
40. Remove detentspring.
41. Remove ballusing astick magnet.
CAUTION: Suitablyidentifyplug,detent
spring andballtotheir fitted positions, do
not interchange withdifferential lock
selector shaftdetent components.
Iffitted
42. Remove 4bolts securing interlocksolenoid
cover, remove coverandBelleville washer.
43. Remove interlocksolenoid.
44. Remove neutrallampwarning switchand
washer.
All transfer boxes
45.Withdraw differential assemblytogetherwith
high/low selectorshaftandfork.    
						

							TRANSFERBOX
OVERHAUL 7
COMPONENT
DISMANTLING
High/low crossshafthousing
1.Slacken locknutandremove neutralwarning
lamp switch -Range RoverClassic only-if
fitted.
2. Remove setscrew securinghigh/lowselector
finger tocross shaft.
3. Withdraw crossshaftfromhousing, recover
high/low selectorfinger.
4. Remove anddiscard Oring. Front
output housing
1.Remove 7bolts securing differential lock
selector sidecover, remove cover.
2.
Up toserial no.288709E:Remove and
discard gasket.
3. Remove 3bolts securing differential lock
selector housing, removehousing andselector
as an assembly.
4. Remove anddiscard Oring from selector
housing.
5. Remove plugsecuring differential lockdetent
spring andball.
6. Remove detentspring.
7. Remove ballusing astick magnet.
CAUTION: Suitablyidentifyplug,detent
spring andballtotheir fitted positions, do
not interchange withhigh/low selector
shaft detent components.    
						

							TRANSFERBOX
8 OVERHAUL
8.Compress differential lockselector forkspring
and remove retaining clipfrom each endof
spring.
9. Withdraw differential lockselector shaftfrom
front output housing, recoverspring.
10. Remove differential lockselector fork.
11.Position propeller shaftflange holding tool
LRT-51-003 tooutput shaftflange.
12. Remove anddiscard self-locking nut.
13.Remove steelandfeltwashers, discardfelt
washer.
14. Remove outputshaftflange together withmud
shield.
NOTE: Areplacement outputflangewillbe
supplied togetherwithnewmud shield
and output shaftoilseal.     
						

							TRANSFERBOX
OVERHAUL 9
15.Using amallet, driveoutput shaftoutoffront
output housing.
NOTE: Ifitis necessary touse ahand
press toremove outputshaft,position
thrust button LRT-370-11/2 betweenshaft
and press mandrel.
16.Noting itsfitted position, removedogclutch
from output shaft.
17. Noting itsfitted position, removebearing
spacer fromoutput shaft.
18.Taking carenottodamage frontoutput
housing, removeanddiscard outputshaftoil
seal.
19. Using suitable circlippliers, remove and
discard circlipretaining outputshaftbearing.
20.Support frontoutput housing onsuitable blocks
of wood.
21. Using asoft metal drift,drive output shaft
bearing outofhousing; discardbearing.      
						

							TRANSFERBOX
10 OVERHAUL
22.Invert frontoutput housing.
23. Using asoft metal drift,drive differential
bearing trackoutofhousing, discardbearing
track.
24. Remove selective shim. Rear
output housing
1.Position propeller shaftflange holding tool
LRT-51-003 tooutput shaftflange.
2. Remove anddiscard self-locking nut.
3.Remove steelandfeltwashers, discardfelt
washer.
4. Remove outputshaftflange together with
circlip.
NOTE: Areplacement outputflangewillbe
supplied togetherwithnewoutput shaft
oil seal.    
						

							TRANSFERBOX
OVERHAUL 11
5.Carefully leverspeedometer drivengearand
housing outofrear output housing.
6. Remove anddiscard Oring.
7. Withdraw speedometer drivengearfrom
housing, removeanddiscard oilseal from
housing.
8. Position rearoutput housing onbed ofhand
press.
9. Position thrustbutton LRT-37-11/2 between
end ofoutput shaftandpress mandrel.
10. Press output shaftoutofhousing.
11. Recover spacerandspeedometer drivegear
from output shaft.     
						

							TRANSFERBOX
12 OVERHAUL
12.Using ascrewdriver insertedinslot inrear
output housing, levermudshield outof
housing.
CAUTION: Discardmudshield ifitis
damaged.
13. Taking carenottodamage rearoutput
housing, removeanddiscard outputshaftoil
seal.
14. Using suitable circlippliers, remove and
discard circlipretaining outputshaftbearing.
15.Support rearoutput housing onsuitable blocks
of wood.
16. Using asoft metal drift,drive output shaft
bearing outofhousing; discardbearing.     
						

							TRANSFERBOX
OVERHAUL 13
Main
casing
1.Support maincasing onsuitable blocksof
wood.
2. Using asoft metal drift,drive differential rear
bearing trackoutofmain casing; discard
bearing track.
3.Invert maincasing.
4. Using asoft metal drift,drive mainshaft input
gear bearing trackoutofmain casing; discard
bearing track. Mainshaft
inputgearbearing housing
1.Secure mainshaft inputgearbearing housing in
a soft-jawed vice.
2. Using asoft metal drift,drive inputgear
bearing trackoutofhousing; discardbearing
track.
3. Remove selective shim.