Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual

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24 OVERHAUL
High/low
selectorforkandshaft
NOTE: Thereisno need toremove
selector forkfrom shaft unless forkor
shaft isto be replaced. Iffork isremoved,
coat threads ofsetscrew withLoctite 290prior to
assembly.
1. Check detentgrooves inshaft forwear.
2. Check high/low selectorfingergroove widthin
shaft: Groove width=16.0 to16.1 mm(0.63 to0.64
in) 3.
Check high/low selectorforkforcracks and
wear.
4. Check high/low selectorforkfinger width:
Finger width=7.37 to7.47 mm(0.290 to0.294
in)   
						

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OVERHAUL 25
Differential
1. Check sunand planet gearsforwear, cracks
and chipping ofteeth.
2. Check crossshafts andrecesses inboth
halves ofdifferential carrierfordamage and
wear.
CAUTION: Ensureplanetgearsare
retained withtheir respective shafts.
3.Check retaining ringfordistortion.
4. Check splines ofdifferential shaftsforwear
and damage.
5. Check teethofhigh/low hubforcracks,
chipping anduneven wear.
6.Check selector forkgroove widthinhigh/low
hub: Groove width=7.5 to7.6 mm (0.295 to0.30 in)
7. Check splines andteeth ofhigh/low selector
sleeve foruneven wear,cracks, damage and
chipping.
8. Check teethofhigh andlowrange gearsfor
cracks, chipping anduneven wear.
9. Check highrange gearbush forwear and
damage.   
						

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26 OVERHAUL
COMPONENT
ASSEMBLING
1. Lubricate allcomponents withrecommended
oil.
Differential 1. Lightly oilthreads ofdifferential bolts.
2.Secure rearhalfofdifferential carrierina
soft-jawed vice.
3. Fiteach planet geartoits respective
cross-shaft, fitnew dished thrustwasher to
each gear.
4. Fitcross-shafts, planetgearsanddished thrust
washers inrear halfcarrier.
CAUTION: Ensurethatcross-shafts arein
their correct fittedposition inrear half
carrier. Donot fitsun gear intorear half
carrier atthis stage.
5.Fitretaining ring.
6. Fita1.05 mm(0.04 in)thick thrust washer to
front halfcarrier sungear, position gearinfront
half carrier.
NOTE: Thisisthe thinnest ofthe thrust
washers available.
7.Fitfront halfcarrier torear ensuring that
alignment marksaretogether.
8. Fitbolts andtighten bydiagonal selection to60
Nm (44lbf.ft).
9.Insert frontoutput shaftintofront halfcarrier,
check thatgears rotate freely.
10. Fitoutput flangeontosplines ofoutput shaft,
do not fitflange nutatthis stage.
11. Fittransmission brakedrumtooutput flange,
secure drumusing 2nuts.
12. Secure alength ofcord around brakedrum,
attach oneendofcord toaspring balance.
13. Tension cordandnote loadtoturn figure
recorded onspring balance whenbrake drum
rotates.
NOTE: Usedgears should rotatesmoothly
whilst newgears willhave anotchy feel
as they rotate.
14.Check figureobtained againstspecified loadto
turn figure:
Used gears =0.45 kg(1.0 lb)
New gears =1.72 kg(3.8 lb)   
						

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OVERHAUL 27
15.
Ifload toturn figure isbelow thatspecified,
proceed asfollows.
16. Remove frontoutput shafttogether withbrake
drum.
17. Remove 8bolts securing fronthalfdifferential
carrier.
18. Remove fronthalfdifferential carrier.
19. Remove fronthalfcarrier sungear andthrust
washer.
20. Select athicker thrustwasher fromtherange
available.
NOTE: 5thicknesses ofthrust washers are
available risinginincrements of0.10 mm
(0.004 in)from 1.05to1.45 mm(0.04 to
0.06 in).
21. Position selected thrustwasher andsungear
in front halfcarrier.
22. Fitfront halfcarrier torear ensuring that
alignment marksaretogether.
23. Fitbolts andtighten bydiagonal selection to60
Nm (44lbf.ft).
24. Fitfront output shaftandbrake drumand
repeat loadtoturn check.
25. Repeat aboveprocedures asnecessary until
load toturn figure isas specified; recordfinal
figure obtained.
26. Remove brakedrumfromfrontoutput shaft,
remove outputshaft.
27. Remove boltssecuring fronthalfcarrier.
28. Remove fronthalfcarrier, remove sungear
and thrust washer.
CAUTION: Keepselected thrustwasher
with sungear.
29.Remove retaining ring.
30. Remove planetgearsandcross shafts.
31.Fita1.05 mm(0.04 in)thick thrust washer to
rear halfcarrier sungear, position gearinrear
half carrier.
32. Fitplanet gears, crossshafts anddished thrust
washers inrear halfcarrier.
CAUTION: Ensurethatplanet gearsare
fitted totheir respective cross-shafts and
cross-shafts arefitted intheir correct
location inhalf carrier.
33.Fitretaining ring.
34. Fitfront halfcarrier torear ensuring that
alignment marksaretogether.
CAUTION: Donot fitsun gear andthrust
washer intofront halfcarrier.
35.Fitbolts andtighten bydiagonal selection to60
Nm (44lbf.ft).   
						

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28 OVERHAUL
36.Invert assembly invice andthen insert rear
output shaftintorear halfcarrier, checkthat
gears rotate freely.
37. Fitoutput flangeontosplines ofoutput shaft,
do not fitflange nutatthis stage.
38. Fittransmission brakedrumtooutput flange,
secure with2nuts.
39. Carry outload toturn check usingsame
method asfor front halfcarrier.
40. When loadtoturn figure iscorrect, recordfinal
figure.
41. Upon completion, fitsun gear andselected
thrust washer tofront halfcarrier.
42. Fitfront halfcarrier ensuring thatalignment
marks aretogether.
43. Fitbolts andtighten bydiagonal selection to60
Nm (44lbf.ft).
44. With differential assembled, fitrear output shaft
and brake drumandcheck overall loadtoturn.
This should beapproximately equaltototal
load toturn figure ofboth front andrear half
carriers addedtogether:
Used gears =0.90 kg(2.0 lb)
New gears =3.44 kg(7.6 lb)
45.Secure rearhalfcarrier inasoft-jawed vice.
46. Fitanew front bearing usingtoolLRT-41-008.   
						

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OVERHAUL 29
47.Support fronthalfcarrier inasoft-jawed vice.
48. Fitlow range gearensuring thatdog teeth on
gear aretowards threaded endofshaft.
NOTE: Useasuitable hollowmandrel tofit
gear ifitis tight onsplines.
49. Fithigh/low hubensuring thatalignment mark
made during dismantling istowards threaded
end ofshaft.
50. Fithigh/low selectorsleeveensuring that
alignment marksonhub andsleeve are
together.
51. Fitbush tohigh range gearensuring thatcollar
on bush ison opposite sideofgear tothe dog
teeth.
52. Fithigh range gearandbush ensuring that
collar onbush istowards threaded endof
shaft.
53. Fitanew rearbearing usingtoolLRT-41-008.
54. Fitanew bearing retainer nut,tighten to72 Nm
(53 lbf.ft) using toolLRT-41-007.
CAUTION: Donot stake nutatthis stage.     
						

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30 OVERHAUL
55.Slide high/low selectorsleeveandhubaway
from lowrange gear.
56. Using feelergauges, determine clearance
between lowrange gearandhigh/low hub:
Clearance =0.05 to0.15 mm(0.002 to0.006
in)
57. Ifclearance isnot asspecified, fitanew low
range gearandhigh/low hubandre-check.58. Slide high/low selectorsleeveandhubaway
from highrange gear.
59. Using feelergauges, determine clearance
between highrange gearandhigh/low hub:
Clearance =0.05 to0.15 mm(0.002 to0.006
in)
60. Ifclearance isnot asspecified, fitnew high
range gearandhigh/low hubandre-check.   
						

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61.Using around nosed punch, stakecollarofnut
into recess indifferential shaft. Main
casing
1.Fitanew differential rearbearing trackusing
tool LRT-51-009.
2. Using astraight edgeandfeeler gauges, check
that bearing trackisrecessed 1.0mm (0.04 in)
below outerfaceofmain casing.
3.Using asuitable mandrel, fitanew mainshaft
input gearbearing track.
CAUTION: Ensurebearing tracksare
seated squarely inrecesses.     
						

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32 OVERHAUL
4.
Lubricate anew mainshaft oilseal with
recommended oil.
5.Invert maincasing andfitoil seal, lipside
facing inwards, usingtoolLRT-37-014. Mainshaft
inputgearbearing housing
1. Ensure bearing trackrecess inhousing is
clean.
2. Position a3.15 mm(0.12 in)thick shim in
bearing housing.
NOTE:Thisisthe thethinnest ofthe
shims available.
3.Using asuitable mandrel, fitnew mainshaft
input gearbearing track.
CAUTION: Ensurebearing trackisseated
squarely inrecess.   
						

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OVERHAUL 33
Mainshaft
inputgearassembly
1. Lubricate newbearings withrecommended oil.
2.Secure handpress LRT-99-002 inavice.
3. Position collarsLRT-41-003 inhand press.
4. Position newbearing oncollars.
NOTE: Smallest diameter ofbearing must
be towards collars.
5.Locate endofmainshaft inbearing, press
mainshaft throughbearing.
6. Repeat aboveprocedure forremaining
bearing. Intermediate
gears.
1. Lubricate newbearings andbearing trackswith
recommended oil.
2.Fitnew circlips intointermediate gears.
CAUTION:Ensurethatcirclips are
correctly seated.
3.Fitnew bearing tracksusingtoolsLRT-41-006
and LRT-99-003.
CAUTION: Ensurebearing tracksarefully
seated against circlips.
4.Retain bearings withintermediate gears.