Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual

							TRANSFERBOX
14 OVERHAUL
Intermediate
gears
1.Secure intermediate gearsinasoft-jawed vice.
2. Using asoft metal drift,drive intermediate shaft
bearing trackoutofgears; discard bearing
track.
3. Remove anddiscard circlip.
4. Repeat aboveprocedure forremaining bearing
track. Mainshaft
inputgearassembly
NOTE: Defender inputgearillustrated.
1.Secure handpress LRT-99-002 inavice.
2. Assemble collarsLRT-41-003 aroundbearing
to be removed.
3. Position mainshaft inhand press, remove and
discard bearing.
4. Repeat aboveprocedure forremaining
bearing.   
						

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OVERHAUL 15
Differential
lockselector
1.Remove anddiscard self-locking nutretaining
selector lever.
2. Remove washerandselector lever.
3. Withdraw selectorfingerandshaft from
housing.
4. Remove anddiscard Oring. Differential
1. Secure differential inasoft-jawed vice.
2. Remove stakingfrombearing retaining nut.
3.Remove nutusing toolLRT-41-007; discard
nut.    
						

							TRANSFERBOX
16 OVERHAUL
4.Secure handpress LRT-99-002 inavice.
5. Secure collarsLRT-41-001 aroundrear
bearing.
NOTE: Thisbearing isadjacent to
threaded endofdifferential shaft.
6.Position differential inhand press withthrust
button, partoftool LRT-41-001 betweenpress
mandrel anddifferential shaft.
7. Press differential outofbearing.
CAUTION: Takecarethatdifferential does
not drop outofbearing.
8. Remove differential frompress, discard
bearing.
9. Remove highrange gearandbush taking care
not todisturb high/low selectorsleeve.
10. Make suitable alignment marksbetween
high/low selectorsleeveandhub.
11. Remove high/lowselectorsleeve.   
						

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OVERHAUL 17
12.Using asuitable pullerandthrust button, part
of tool LRT-41-001, removehigh/low huband
low range gear.
13.Secure handpress LRT-99-002 inavice.
14. Assemble collarsLRT-41-002 aroundfront
bearing.
NOTE: Thisbearing isadjacent tosplined
end ofdifferential shaft.
15.Position differential inhand press withthrust
button, partoftool LRT-41-001 betweenpress
mandrel anddifferential shaft.
16. Press differential outofbearing.
CAUTION: Takecarethatdifferential does
not drop outofbearing.
17. Remove differential frompress, discard
bearing.    
						

							TRANSFERBOX
18 OVERHAUL
18.Secure rearhalfofdifferential carrierina
soft-jawed vice.
19. Make suitable alignment marksbetween front
and rear halves ofdifferential carrier.
20. Remove 8bolts securing fronthalfofcarrier to
rear, remove carrier.
21. Suitably identifyfrontsungear tofront halfof
carrier, remove sungear.
22. Remove anddiscard thrustwasher.
23. Suitably identifyeachplanet geartoits shaft
and fitted position ofeach cross shafttorear
half ofcarrier.
24. Remove retaining ring.
25. Remove planetgearsandcross shafts, remove
and discard dishedthrustwashers.
26. Suitably identifyrearsungear torear halfof
carrier, remove sungear.
27. Remove anddiscard thrustwasher. INSPECTING
COMPONENTS
1. Clean allcomponents, removealltraces of
silicone sealantusingsuitable solventanda
plastic scraper.
2.
Up toserial no.288709E:Remove alltraces of
gasket usingsuitable gasketremoval spray
and aplastic scraper.
3. Clean alltraces ofLoctite andsealant from
threads ofbolts andtapped holes.Ensure
holes areclean anddry.
CAUTION: Donot use atap toclear
threads intapped holes.
4.Check allcasings andcovers forcracks and
damage.
5. Replace anycomponent foundtobe damaged.  
						

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OVERHAUL 19
Intermediate
gearsandshaft
1. Check gearteeth forcracks, chipping and
uneven wear.
2. Check shaftforwear andthreads fordamage. Mainshaft
inputgear
1. Check gearteeth forcracks, chipping and
uneven wear.
2. Check thatcross drillings inshaft areclear.
NOTE: Earlytransfer boxesfittedwithan
oil feed plate donot have cross drilled
shafts. Ifareplacement inputgearand
shaft isto be fitted, theshaft willbecross drilled
and itwill notbenecessary tofitthe oilfeed
plate.
Defender only
3.Check thatends ofdog teeth arenot
rounded-off orchipped.  
						

							TRANSFERBOX
20 OVERHAUL
High/low
crossshaftandhousing
1. Check mating surfaces ofcross shaftand
drilling inhousing forwear.
2. Check corepluginhousing forsigns of
leakage orcorrosion, applyLoctite 326to
replacement plug.
3.Check high/low selectorfingerforwear.
4. Measure acrosswidestportion offinger:
Finger width=15.90 to15.95 mm(0.625 to
0.627 in) Front
output housing anddifferential lock
selector
1. Check bearing trackrecesses inhousing for
damage, rectifyorreplace housing as
necessary.
2. Check differential lockselector fingershaftand
drilling inhousing forwear.
3.Check differential lockselector fingerforwear.
4. Measure acrosswidestportion offinger:
Finger width=15.90 to15.95 mm(0.625 to
0.627 in)
5.Check differential lockselector fingergroove
width indifferential lockselector shaft:
Groove width=16.0 to16.1 mm(0.63 to0.64
in)    
						

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OVERHAUL 21
6.Check detentgrooves indifferential lock
selector shaftforwear.
7. Check differential lockdetent ballforflat spots.
8. Check detentspringfordistortion.
9. Check differential lockselector forkforcracks
and wear.
10. Check differential lockselector forkfinger
width: Finger width=7.92 to7.97 mm(0.311 to0.313
in)
11. Check differential lockselector forkspring for
distortion andclips forwear anddamage.
12. Check springfreelength:
Free length =84.58 mm(3.33 in)
13. Check dogclutch internal teethandgrooves for
wear anddamage.    
						

							TRANSFERBOX
22 OVERHAUL
14.Check dogclutch selector forkgroove width:
Groove width=8.05 to8.20 mm(0.32 to0.33
in)
15. Check threads andsplines ofoutput shaftfor
damage andwear.
16. Check dogclutch teethonshaft forwear and
damage. Rear
output housing
1. Check bearing trackrecess inhousing for
damage, rectifyorreplace housing as
necessary.
2. Check speedometer driveanddriven gearsfor
damage andwear.
3. Check splines andthreads ofoutput shaftfor
damage andwear.  
						

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OVERHAUL 23
Main
casing
1. Check bearing trackrecesses inmain casing
for damage, rectifyorreplace casingas
necessary.
2. Remove drainplug,discard sealingwasher.
3. Fitnew sealing washer, fitdrain plugand
tighten to30 Nm (22lbf.ft).
4. Remove fillerplug, check threads fordamage.
5. Fitbut donot fully tighten fillerplug.
6. Check thatlocating dowelsarefitted incasing
and thatblade offront output housing dowelis
positioned asshown.
7. Remove oiltemperature switch-if fitted,
remove sealantfromthreads ofswitch and
main casing.
8. Apply Hylomar PL32sealant tothreads, fitand
tighten switch.
9. Check high/low detentballforflat spots.
10. Check detentspringfordistortion. Mainshaft
inputgearbearing housing
1. Check bearing trackrecess inhousing for
damage, rectifyorreplace housing as
necessary.