Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

TRANSFER BOX
12
DESCRIPTION AND OPERATION DESCRIPTION
Introduction
The LT230T transfer box is mounted at the rear of
the main gearbox and transmits drive to the front
and rear axles via the propeller shafts.
Construction
The transfer box comprises three main assemblies,
the main casing, front output housing and rear
output housing.
The main casing carries the mainshaft input gear,
the intermediate gears and the differential together
with the high/low range gears, selector shaft and
fork.
The front output...

TRANSFER BOX
DESCRIPTION AND OPERATION13
Front output housing assembly
The front output shaft is supported in the front output
housing by a single bearing and is splined into the
differential front shaft.
The high/low cross shaft is located in a housing
bolted to the top of the output housing and is
connected to the high/low selector finger which
locates in a slot in the selector shaft.
The differential lock selector housing is also bolted
to the top of the front output housing, the selector
finger...

TRANSFER BOX
14
DESCRIPTION AND OPERATION Power flow - transfer box in LOW ratio 

TRANSFER BOX
DESCRIPTION AND OPERATION15
Power flow - transfer box in HIGH ratio 

TRANSFER BOX
OVERHAUL1
TRANSFER BOX DISMANTLING
1.Clean exterior of transfer box.
2.Drain and discard the oil, refit drain plug.
3.Loosen bolt to release transmission brake
adjustment.
4.Remove countersunk screw securing
transmission brake drum, remove drum.
NOTE: 2 screws may be fitted.
5.Make suitable alignment marks between
transmission brake backplate and rear output
housing.
6.Remove 4 bolts securing transmission brake
backplate, remove backplate.
7.Remove Allen screw securing vehicle speed
sensor -...

TRANSFER BOX
2
OVERHAUL
11.Release staking from intermediate shaft nut,
remove and discard nut.
12.Remove bolt securing anti-rotation plate,
remove plate.
13.Using a soft metal drift on threaded end of
intermediate shaft, drive shaft out of main
casing.
14.Remove and discard’O’ring from intermediate
shaft.
15.Remove and discard’O’ring from main casing.
16.Wrap a suitable length of wire around
intermediate gears and using assistance, lift
gears out of main casing.
NOTE: Collapsible spacer illustrated....

TRANSFER BOX
OVERHAUL3
NOTE: Discovery cover plate illustrated.
19.Make suitable alignment marks between cover
plate/power take-off cover, mainshaft input
gear bearing housing and main casing.
20.Noting fitted position of stud nut and
harness/speedometer cable clip, remove 5
bolts and stud nut securing cover plate/ power
take-off cover, recover clip.
21.Remove cover plate/power take-off cover.
22.Up to serial no. 288709E:Remove and discard
gasket.
23.Remove oil feed plate - if fitted, remove and...

TRANSFER BOX
4
OVERHAUL
27.Remove mainshaft input gear together with
taper roller bearings.
NOTE: Input gear fitted to Defender
transfer boxes has an additional dog tooth
gear - see inset on illustration.
28.Remove and discard mainshaft oil seal from
main casing.
CAUTION: Do not remove mainshaft input
gear bearing track at this stage.
NOTE: Low detect switch fitted to early
boxes illustrated.
29.Remove 6 bolts securing high/low cross shaft
housing.
30.Remove cross shaft housing.
31.Up to serial no....

TRANSFER BOX
OVERHAUL5
32.Loosen locknut and remove differential lock
warning lamp switch from front output housing.
NOTE: On later boxes, locknut is replaced
by a spacer.
33.Noting fitted position of longest bolt, remove 8
bolts securing front output housing to main
casing.
34.Remove front output housing.
NOTE: Dowel located.35.Up to serial no. 288709E:Remove and
discard gasket.
CAUTION: Do not carry out further
dismantling of front output housing at this
stage.
36.Noting their fitted position, remove...