Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

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OVERHAUL
9.Remove high range gear and bush taking care
not to disturb high/low selector sleeve.
10.Make suitable alignment marks between
high/low selector sleeve and hub.
11.Remove high/low selector sleeve.
12.Using a suitable puller and thrust button, part
of toolLRT-41-001,remove high/low hub and
low range gear. 

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13.Secure hand pressLRT-99-002in a vice.
14.Assemble collarsLRT-41-002around front
bearing.
NOTE: This bearing is adjacent to splined
end of differential shaft.
15.Position differential in hand press with thrust
button, part of toolLRT-41-001between press
mandrel and differential shaft.
16.Press differential out of bearing.
CAUTION: Take care that differential does
not drop out of bearing.
17.Remove differential from press, discard
bearing.
18.Secure rear half of differential...

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OVERHAUL INSPECTING COMPONENTS
1.Clean all components, remove all traces of
silicone sealant using suitable solvent and a
plastic scraper.
2.Up to serial no. 288709E:Remove all traces of
gasket using suitable gasket removal spray
and a plastic scraper.
3.Clean all traces of Loctite and sealant from
threads of bolts and tapped holes. Ensure
holes are clean and dry.
CAUTION: Do not use a tap to clear
threads in tapped holes.
4.Check all casings and covers for cracks and
damage.
5.Replace...

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Mainshaft input gear
1.Check gear teeth for cracks, chipping and
uneven wear.
2.Check that cross drillings in shaft are clear.
NOTE: Early transfer boxes fitted with an
oil feed plate do not have cross drilled
shafts. If a replacement input gear and
shaft is to be fitted, the shaft will be cross drilled
and it will not be necessary to fit the oil feed
plate.
Defender only
3.Check that ends of dog teeth are not
rounded-off or chipped.High/low cross shaft and housing
1.Check mating...

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OVERHAUL Front output housing and differential lock
selector
1.Check bearing track recesses in housing for
damage, rectify or replace housing as
necessary.
2.Check differential lock selector finger shaft and
drilling in housing for wear.
3.Check differential lock selector finger for wear.
4.Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in)
5.Check differential lock selector finger groove
width in differential lock selector shaft:
Groove width =...

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10.Check differential lock selector fork finger
width:
Finger width = 7.92 to 7.97 mm (0.311 to 0.313
in)
11.Check differential lock selector fork spring for
distortion and clips for wear and damage.
12.Check spring free length:
Free length = 84.58 mm (3.33 in)
13.Check dog clutch internal teeth and grooves for
wear and damage.14.Check dog clutch selector fork groove width:
Groove width = 8.05 to 8.20 mm (0.32 to 0.33
in)
15.Check threads and splines of output shaft for
damage and...

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OVERHAUL Rear output housing
1.Check bearing track recess in housing for
damage, rectify or replace housing as
necessary.
2.Check speedometer drive and driven gears for
damage and wear.
3.Check splines and threads of output shaft for
damage and wear.Main casing
1.Check bearing track recesses in main casing
for damage, rectify or replace casing as
necessary.
2.Remove drain plug, discard sealing washer.
3.Fit new sealing washer, fit drain plug and
tighten to 30 Nm (22 lbf.ft).
4.Remove...

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Mainshaft input gear bearing housing
1.Check bearing track recess in housing for
damage, rectify or replace housing as
necessary.High/low selector fork and shaft
NOTE: There is no need to remove
selector fork from shaft unless fork or
shaft is to be replaced. If fork is removed,
coat threads of setscrew with Loctite 290 prior to
assembly.
1.Check detent grooves in shaft for wear.
2.Check high/low selector finger groove width in
shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64
in) 

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OVERHAUL 3.Check high/low selector fork for cracks and
wear.
4.Check high/low selector fork finger width:
Finger width = 7.37 to 7.47 mm (0.290 to 0.294
in)Differential
1.Check sun and planet gears for wear, cracks
and chipping of teeth.
2.Check cross shafts and recesses in both
halves of differential carrier for damage and
wear.
CAUTION: Ensure planet gears are
retained with their respective shafts.
3.Check retaining ring for distortion.
4.Check splines of differential shafts for wear...

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COMPONENT ASSEMBLING
1.Lubricate all components with recommended
oil.
Differential
1.Lightly oil threads of differential bolts.
2.Secure rear half of differential carrier in a
soft-jawed vice.
3.Fit each planet gear to its respective
cross-shaft, fit new dished thrust washer to
each gear.
4.Fit cross-shafts, planet gears and dished thrust
washers in rear half carrier.
CAUTION: Ensure that cross-shafts are in
their correct fitted position in rear half
carrier. Do not fit sun gear...