Land Rover Lt230t Transfer Box Overhaul 2nd Edition Rover Manual

							TRANSFERBOX
44 OVERHAUL
10.Compress differential lockselector springand
fit to selector fork.
11. Locate fingersofselector forkingroove indog
clutch.
12. Fitdifferential lockselector shaftensuring end
of shaft islocated inrecess inrear ofhousing.
13. Rotate selector shaftuntilthetwo flats forthe
retaining clipsareatright angles tothe cover
plate mating face.
14.Compress selectorspringandfitretaining clips
at each endofspring.
CAUTION: Ensureendsofspring arefully
seated inrecess inclips.
15. Fitdifferential lockdetent balland spring.
16. Apply Loctite 290tothreads ofdetent plug.
17. Fitand tighten detentplugthen unscrew 2full
turns.    
						

							TRANSFERBOX
OVERHAUL 45
18.Ensure Oring iscorrectly locatedon
differential lockselector housing.
19. Fitdifferential lockselector assembly ensuring
that selector fingerislocated inrecess in
differential lockselector shaft.
20. Apply Loctite 290tothreads ofbolts.
21. Fitbolts andtighten to25 Nm (18lbf.ft).
22. Operate differential lockselector leverand
check thatdifferential lockdetent ballcan be
felt topositively engageanddisengage with
grooves inselector shaft;screw detent plugin
or out until setting iscorrect.
23. Apply Hylomar PL32sealant tothreads of
differential lockwarning lampswitch, fitand
tighten switch.
CAUTION: Donot allow sealant tocontact
switch plunger, donot tighten locknut or
fit differential locksidecover untilswitch
has been adjusted.
24.Uptoserial no.288709E:Apply grease tonew
high/low selectorhousing gasket,position
gasket onfront output housing.
25.
From serial no.288709E:Apply Hylosil RTV
102 sealant tomating flangeofhigh/low
selector housing.
26. Fithousing ensuring thathigh/low selector
finger islocated inrecess inhigh/low selector
shaft.
27. Fit6bolts andtighten to25 Nm (18lbf.ft).    
						

							TRANSFERBOX
46 OVERHAUL
Intermediate
gears
1.Insert anew collapsible spacerinto
intermediate gears,fitbearings intobearing
tracks.
2. Wrap asuitable lengthofwire around
intermediate gearsandusing assistance, lower
gears intomain casing ensuring thatthey are
meshing withinput anddifferential gears.
CAUTION: Donot remove wireatthis
stage.
3. Lubricate newOrings withrecommended oil
and fitto intermediate shaftandmain casing.    
						

							TRANSFERBOX
OVERHAUL 47
4.Raise intermediate gearsuntildummy shaft
LRT-41-004 canbeinserted fromfrontoutput
housing sideofmain casing.
5. Fitintermediate shaft,driftshaft intoposition
whilst atthe same timeexpelling dummyshaft
LRT-41-004 .
CAUTION:EnsureOring isnot displaced
from main casing.
6.Remove wirefrom around intermediate gears.
7.Rotate intermediate shaftuntilretaining plate
can belocated onflat onshaft.
8. Apply Loctite 290tothreads ofretaining plate
bolt.
9. Fitbolt and tighten to25 Nm (18lbf.ft).
10. Fitanew intermediate shaftnut.
11. Tighten intermediate shaftnutinsmall stages
until allend-float isremoved fromintermediate
gears.
CAUTION: Checkend-float ofintermediate
gears between eachstage, donot
continue tightening nutafter end-float is
removed. Donot stake nutatthis stage.
12.Setintermediate gearbearing pre-load-See
Intermediate gearbearing pre-load.    
						

							TRANSFERBOX
48 OVERHAUL
Intermediate
gearbearing pre-load
1. Select neutral.
2. Screw asuitable boltintotapped holeinend of
tool LRT-41-005.
3.Insert toolLRT-41-005 inend ofmainshaft.
4. Using asuitable torquemeterontool
LRT-41-005, checkandrecord torquetoturn
mainshaft inputgears.
5. Tighten theintermediate shaftnutinsmall
stages checking thetorque toturn theinput
gears untilthemainshaft inputgeartorque to
turn figure recorded inoperation 4has
increased by1.25 Nm(10lbf.in).
CAUTION: Takegreat carenotto
overtighten nutasthis willcause
excessive bearingpre-load. Iftorque to
turn figure isinadvertently exceeded,anew
collapsible spacermustbefitted.
6.When torque toturn figure -intermediate gear
bearing pre-load iscorrect, stakeflange of
intermediate shaftnutinto recess in
intermediate shaft.
7. Remove toolLRT-41-005.
NOTE: Discovery coverplateillustrated.
8.Uptoserial no.288709E:Fitand tighten 2
countersunk screwstosecure mainshaft input
gear bearing housing.
9. Remove 2bolts used totemporarily secure
mainshaft inputgearbearing housing.
10.
From serial no.288709E:Remove mainshaft
input gearbearing housing thenapply Hylosil
2000 sealant tomain casing mating faceof
bearing housing; positionhousing onmain
casing ensuring thatreference marksare
aligned. Fitand tighten 2countersunk screws-
if fitted.
If fitted
11. Lubricate anew Oring with recommended oil
and fitto oil feed plate.
12. Fitoilfeed plate ensuring thatword TOPis
towards topofmain casing andspigots are
located incut-outs.
NOTE: Ifareplacement inputgearhaving
a cross-drilled shaftisto be fitted, discard
oil feed plate andOring.   
						

							TRANSFERBOX
OVERHAUL 49
Alltransfer boxes
13.Apply Hylosil RTV102sealant orposition new,
dry gasket tomating faceofcover plate/power
take-off cover.Position plate/cover onbearing
housing ensuring thatreference marksare
aligned.
14. Position cliptostud nut.
15. Apply Loctite 290tothreads ofbolts andstud
nut.
16. Fit5bolts andstud nutand tighten bydiagonal
selection to25 Nm (18lbf.ft).
NOTE: Theseboltsarethreaded tohead.
Bottom cover
1.
Up toserial no.288709E:Position newbottom
cover gasket, dryonmain casing.
2.
From serial no.288709E:Apply Hylosil RTV
102 sealant tomating faceofbottom cover.
3.Fitbottom cover.
4. Apply Loctite 290tothreads ofbottom cover
securing bolts.
5. Fitbolts inpositions shownandtighten by
diagonal selection to25 Nm (18lbf.ft).   
						

							TRANSFERBOX
50 OVERHAUL
High/low
selectorshaftdetent
1.Fitdetent balland spring.
2. Apply Loctite 290tothreads ofdetent plug.
3. Fitand tighten plugthen unscrew 2full turns.
4. Operate high/low selectorleverandcheck that
detent ballcan befelt topositively engageand
disengage withgrooves inselector shaft;screw
plug inor out until setting iscorrect. Interlock
solenoid-if fitted
1. Position interlock solenoid inmain casing.
2. Apply Hylosil RTV102tomating faceof
solenoid cover.
3. Fitsolenoid coverandBelleville washer,fit
bolts andtighten to10 Nm (8lbf.ft).   
						

							TRANSFERBOX
OVERHAUL 51
Neutral
warning lampswitch -if fitted -not
Range RoverClassic
1.Apply Hylosil PL32sealant tothreads of
switch.
2. Fitwasher, fitand tighten switch. Differential
lockwarning lampswitch -adjust
1. Move differential lockselector forkto
differential lockedposition.
2. Connect a12V testlamp andbattery to
differential lockswitch.
3. Screw switchinuntil testlamp isilluminated
then screw switch inafurther 1/2turn; tighten
locknut.
4. Disengage differentiallock,check thattest
lamp isextinguished.
5. Remove testlamp.
6.
Up toserial no.288709E:Apply grease toa
new gasket andfitto differential lockside
cover.
7.
From serial no.288709E:Apply Hylosil RTV
102 sealant tomating faceofdifferential lock
side cover.
8. Fitside cover, fitbolts andtighten to25 Nm (18
lbf.ft).    
						

							TRANSFERBOX
52 OVERHAUL
Transmission
brake
1. Apply Hylosil RTV102sealant tomating face
of rear output housing.
2.Position brakebackplate onrear output
housing ensuring thatalignment marksare
together.
3. Fit4bolts andtighten to70 Nm (52lbf.ft).
4. Fittransmission brakedrum, fitcountersunk
screw andtighten.
NOTE: Earlytransfer boxes-2 screws are
fitted.  
						

							TRANSFERBOX
DATA, TORQUE &TOOLS 1
DATA High/low
selectorfingerwidth 15.90to15.95 mm
.................. 0.625to0.627 in
High/low selectorforkfinger width 7.37to7.47 mm
............... 0.290to0.294 in
High/low selectorshaftgroove width 16.0to16.1 mm
............. 0.63to0.64 in
High/low selectorhubgroove width 7.5to7.6 mm
.............. 0.295to0.30 in
Differential lockselector fingerwidth 15.90to15.95 mm
............. 0.625to0.627 in
Differential lockselector shaftgroove width 16.0to16.1 mm
....... 0.63to0.64 in
Differential lockselector forkfinger width 7.92to7.9
......... 0.311to0.313 in
Differential lockselector springfreelength 84.58mm
........ 3.33in
Dog clutch selector forkgroove width 8.05to8.20 mm
............ 0.32to0.33 in
Differential frontandrear halfcarrier gearsload
to turn :
Used gears 0.45kg
............................... 1.0 lb
New gears 1.72kg
................................ 3.8 lb
Thrust washer thicknesses available 1.05to1.45 mm
............. 0.04to0.06 in
In increments of: 0.10mm
........................... 0.004in
Total loadtoturn -both sungears fitted:
Used gears 0.90kg
............................... 2.0 lb
New gears 3.44kg
................................ 7.6 lb
Low range geartohigh range hubclearance 0.05to0.15 mm
...... 0.002to0.006 in
High range geartohigh/low hubclearance 0.05to0.15 m
........ 0.002to0.006 in
Mainshaft inputgearbearing pre-load 0.05mm
............ 0.002in
Mainshaft inputgearbearing shimthicknesses
available 3.15to4.00 mm
.................................. 0.12to0.16 in
In increments of: 0.05mm
........................... 0.002in
Differential bearingpre-load 0.05mm
................... 0.002in
Differential shimthicknesses available 2.00to3.25 mm
........... 0.08to0.13 in
In increments of 0.05mm
............................ 0.002in
Intermediate gearbearing pre-load -
An increase onmainshaft inputgear
initial torque toturn of 1.25Nm
........................ 10 lbf.in