Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual

							TRANSFERBOX
34 OVERHAUL
Rear
output housing
1. Heat rearoutput housing to100 °C (210 °F).
2. Fitnew output shaftbearing usingtool
LRT-41-011.
3. Allow housing toair cool.
4. Fitnew bearing retaining circlipensuring itis
seated ingroove. 5.
Lubricate anew output shaftoilseal with
recommended oil.
6.Fitoilseal using toolLRT-41-012.
NOTE: Useendoftool marked REARto
fit oil seal.
7.Check thatoilseal isjust contacting circlip.
8.Slide speedometer drivegearandspacer onto
output shaft.    
						

							TRANSFERBOX
OVERHAUL 35
9.Position rearoutput housing onbed ofhand
press.
10. Locate threaded endofoutput shaftinbearing.
11. Position thrustbutton LRT-37-11/2 between
end ofoutput shaftandpress mandrel.
12. Press output shaftintobearing.
13. Fitmud shield withopen faceofshield towards
oil seal.
CAUTION: Donot fitoutput shaftflange at
this stage.    
						

							TRANSFERBOX
36 OVERHAUL
14.Fitspeedometer drivengearintorear output
housing ensuring thatgear teeth areengaged
with drive gear.
15. Lubricate anew Oring with recommended oil
and fitto driven gearhousing.
16. Fitdriven gearhousing.
17. Lubricate anew oilseal withrecommended oil,
fit seal withliptowards drivengearhousing. Front
output housing
CAUTION: Donot carry outassembly
operations untildifferential bearing
pre-load hasbeen established
-See
Differential bearingpre-load.
1.Heat frontoutput housing to100 °C (210 °F).
2. Fitnew output shaftbearing usingtool
LRT-41-011.
3. Allow housing toair cool.
4. Fitnew bearing retaining circlipensuring itis
fully seated ingroove.   
						

							TRANSFERBOX
OVERHAUL 37
5.
Lubricate anew output shaftoilseal with
recommended oil.
6.Fitoilseal using toolLRT-41-012.
NOTE: Useendoftool marked FRONT to
fit oil seal.
7.Check thatoilseal isjust contacting circlip.
8. Position selected shiminfront output housing.
9.Fitdifferential frontbearing trackusing tool
LRT-54-003.
10. Fitbearing spacertooutput shaftensuring that
chamfer onspacer istowards threaded endof
shaft.
11. Fitdog clutch ensuring thatflange onclutch is
towards splinedendofshaft.
12. Using amallet, driveoutput shaftintobearing.     
						

							TRANSFERBOX
38 OVERHAUL
High/low
crossshafthousing
1. Lubricate crossshaftandnew Oring with
recommended oil.
2.Insert crossshaftintohousing, position
high/low selectorfingeronshaft.
3. FitO ring toshaft, locate endofshaft in
hollow plug.
4. Slide Oring toend ofshaft.
5. Align holeinhigh/low selectorfingerwith
recess incross shaft.
6. Apply Loctite 290tothreads ofsetscrew, fit
and tighten screw.
7. Apply Hylomar PL32sealant tothreads of
neutral warning lampswitch -Range Rover
Classic only-if fitted. Fitswitch, donot tighten
locknut untilswitch hasbeen adjusted.
NOTE: Switch mustbeadjusted after
transfer boxisinstalled invehicle.
Differential lockselector
1.Lubricate newOrings withrecommended oil,
fit to selector fingershaftandhousing.
2. Insert selector fingershaftintohousing.
3. Fitselector leverensuring thatrelative
positions oflever andfinger areasshown.
4. Fitwasher andnew self-locking nut,tighten nut
to 15 Nm (11lbf.ft).   
						

							TRANSFERBOX
OVERHAUL 39
TRANSFER
BOXASSEMBLING
1. Lubricate allcomponents withrecommended
oil.
CAUTION: Whereuseofgaskets is
specified, gasketsmustbefitted; donot
use sealant.
Mainshaft inputgearbearing pre-load
1.Position mainshaft inputgearassembly inmain
casing.
2.
Up toserial no.288709E:Fitanew mainshaft
input gearbearing housing gasket,dryonmain
casing.
3.
All transfer boxes:Fitmainshaft inputgear
bearing housing ensuring reference marksare
aligned.
4. Fit2M10 x25 m m bolts andtighten to25 Nm
(18 lbf.ft).
5. Position suitableDTIwith stylus ofgauge
contacting endofmainshaft, pushmainshaft
rearwards andzero gauge.
6. Push mainshaft forwardsandnote gauge
reading. 7.
Calculate thickness ofshim required usingthe
formula A+B +C =D where:
A =Thickness ofinstalled shim-3.15 mm
(0.12 in)
B =Recorded end-float
C =Required pre-load-0.05 mm(0.002 in)
D =Thickness ofshim required
8. Ifan alternative shimisrequired toestablish
correct end-float, proceedasfollows:
NOTE: Donot remove mainshaft input
gear bearing housing ifbearing pre-load is
correct.
9. Remove 2bolts, remove mainshaft inputgear
bearing housing.
NOTE:Uptoserial no.288709E, retain
gasket onmain casing.
10.Using asoft metal drift,carefully driveinput
gear bearing trackoutofbearing housing,
remove shim.
CAUTION: Ifbearing trackisdamaged
during thisoperation, anew track mustbe
fitted.
11. Select required shimfromtherange available.
NOTE: Shimsareavailable from3.15to
4.00 mm(0.12 to0.16 in)thickness rising
in increments of0.05 mm(0.002 in).
12.Fitselected shimandusing asuitable mandrel,
fit input gearbearing track.
13. Fitmainshaft inputgearbearing housing and
temporarily secureusing2M10 x25 m m bolts
tightened to25 Nm (18lbf.ft).   
						

							TRANSFERBOX
40 OVERHAUL
Rear
output housing
1.
Up toserial no.288709E:Position anew
gasket, dryonmain casing.
2.
From serial no.288709E:Apply Hylosil RTV
102 sealant tomating flangeofrear output
housing.
3. Fitrear output housing tomain casing.
NOTE: Dowellocated.
4.Apply Loctite 290tothreads ofbolts and
shoulder bolt.
5. Fitwashers to2bolts.
6. Fitbolts andtighten bydiagonal selection to25
Nm (18lbf.ft).
7. Fitoutput flange, newfeltand steel washers to
output shaft.
8. Fitanew self-locking nut.
9.Position propeller shaftflange holding tool
LRT-51-003 tooutput flange.
10. Restrain flange,tightennutto162 Nm(120
lbf.ft).
11. Lubricate anew Oring with recommended oil
and fitto vehicle speedsensor -if fitted.
12. Fitvehicle speedsensor -if fitted.
13. Fitand tighten Allenscrew.    
						

							TRANSFERBOX
OVERHAUL 41
Differential
bearingpre-load
1.Position high/low selectorshaftandforkto
differential ensuringthatfingers ofselector fork
are located inhigh/low selectorsleeve.
2. Position high/low selectorshaftanddifferential
in main casing ensuring thatsplines ofrear
output shaftareengaged indifferential.
3. Position newdifferential frontbearing outer
track onbearing ensuring thattrack isseated
squarely.
4. Position settingblock,toolLRT-41-014/3 on
main casing.
5. Screw pillarLRT-41-014/4 intotapped holein
main casing.
6. Assemble DTILRT-99-006 topillar.
7. Position stylusofDTI tosetting block,zero
gauge.
8. Position stylusofgauge onfront bearing outer
track, record reading obtained.
9. Position stylusofgauge onopposite sideof
bearing track,record reading obtained.
CAUTION: Ensurethatbearing outertrack
is not disturbed whencarrying outabove
operations.
10. Establish averageofthe 2readings, record
figure obtained.     
						

							TRANSFERBOX
42 OVERHAUL
11.Position frontoutput housing asshown.
12.
Up toserial no.288709E:Position anew
gasket, dry,onfront output housing.
13. Position depthblock, toolLRT-41-014/2 and
cross-bar, toolLRT-41-014/1 onfront output
housing.
14. Position DTILRT-99-006 oncross-bar
LRT-41-014/1 .
15. Zero DTIondepth blockLRT-41-014/2.
16. Position DTItocross-bar LRT-41-014/1, record
reading obtained.
17. Remove tools.
18.
Up toserial no.288709E:Remove andretain
gasket.
19. Using theformula:
3.05 mm(0.120 in)+B -A =D where:
B =Height difference recordedbetweendepth
block andcross bar
A =Average ofreadings todifferential front
bearing outertrack
D =Thickness ofshim required togive
differential bearingpre-load of0.05 mm(0.002
in)
20. From resultant figureobtained, select
appropriate thicknessshimfromtherange
available.
NOTE: Shimsareavailable from2.00to
3.25 mm(0.08 to0.13 in)thickness rising
in increments of0.05 mm(0.002 in).
21.Retain selected shimanddifferential front
bearing outertrackwithfront output housing.
22.
Up toserial no.288709E:Retain gasket with
front output housing.
23. Carry outassembly offront output housing
-
See Component assembling.  
						

							TRANSFERBOX
OVERHAUL 43
Front
output housing
1.Uptoserial no.288709E:Fitgasket used
when determining differentialbearingpre-load,
dry, tomain casing.
2.
From serial no.288709E:Apply Hylomar RTV
102 sealant tomating flangeoffront output
housing.
All transfer boxes
3.Fitfront output housing ensuring thatsplines of
output shaftareengaged indifferential andthat
internal splinesofdog clutch areengaged with
teeth ofoutput shaft.
4. Apply Loctite 290tothreads ofbolts, fitbolts
noting thatlongest boltisinserted through
high/low selectorfingerhousing.
5. Tighten boltsbydiagonal selection to25 Nm
(18 lbf.ft).
6. Fitoutput flange, newfeltand steel washers.
7. Fitanew self-locking nut.
8.Position propeller shaftflange holding tool
LRT-51-003 tooutput flange.
9. Restrain flange,tightennutto162 Nm(120
lbf.ft).