Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

TRANSFER BOX
36
OVERHAUL High/low cross shaft housing
1.Lubricate cross shaft and new’O’ring with
recommended oil.
2.Insert cross shaft into housing, position
high/low selector finger on shaft.
3.Fit’O’ring to shaft, locate end of shaft in
hollow plug.
4.Slide’O’ring on to end of shaft.
5.Align hole in high/low selector finger with
recess in cross shaft.
6.Apply Loctite 290 to threads of setscrew, fit
and tighten screw.
7.Apply Hylomar PL32 sealant to threads of low
detect switch - if fitted. Fit switch,...

TRANSFER BOX
OVERHAUL37
TRANSFER BOX ASSEMBLING
1.Lubricate all components with recommended
oil.
CAUTION: Where use of gaskets is
specified, gaskets must be fitted; do not
use sealant.
Mainshaft input gear bearing pre-load
1.Position mainshaft input gear assembly in main
casing.
2.Up to serial no. 288709E:Fit a new mainshaft
input gear bearing housing gasket, dry on main
casing.
3.All transfer boxes:Fit mainshaft input gear
bearing housing ensuring reference marks are
aligned.
4.Fit 2 M10 x 25 mm bolts...

TRANSFER BOX
38
OVERHAUL Rear output housing
1.Up to serial no. 288709E:Position a new
gasket, dry on main casing.
2.From serial no. 288709E:Apply Hylosil RTV
102 sealant to mating flange of rear output
housing.
3.Fit rear output housing to main casing.
NOTE: Dowel located.
4.Apply Loctite 290 to threads of bolts and
shoulder bolt.
5.Fit washers to 2 bolts.
6.Fit bolts and tighten by diagonal selection to 45
Nm (33 lbf.ft).
7.Fit output flange, new felt and steel washers to
output shaft.
8.Fit a new...

TRANSFER BOX
OVERHAUL39
Differential bearing pre-load
1.Position high/low selector shaft and fork to
differential ensuring that fingers of selector fork
are located in high/low selector sleeve.
2.Position high/low selector shaft and differential
in main casing ensuring that splines of rear
output shaft are engaged in differential.
3.Position new differential front bearing outer
track on bearing ensuring that track is seated
squarely.
4.Position setting block, toolLRT-41-014/3on
main casing.
5.Screw...

TRANSFER BOX
40
OVERHAUL
11.Position front output housing as shown.
12.Up to serial no. 288709E:Position a new
gasket, dry, on front output housing.
13.Position depth block, toolLRT-41-014/2and
cross-bar, toolLRT-41-014/1on front output
housing.
14.Position DTILRT-99-006on cross-bar
LRT-41-014/1.
15.Zero DTI on depth blockLRT-41-014/2.
16.Position DTI to cross-barLRT-41-014/1,record
reading obtained.
17.Remove tools.
18.Up to serial no. 288709E:Remove and retain
gasket.
19.Using the formula:
3.05 mm...

TRANSFER BOX
OVERHAUL41
Front output housing
1.Up to serial no. 288709E:Fit gasket used
when determining differential bearing pre-load,
dry, to main casing.
2.From serial no. 288709E:Apply Hylomar RTV
102 sealant to mating flange of front output
housing.
All transfer boxes
3.Fit front output housing ensuring that splines of
output shaft are engaged in differential and that
internal splines of dog clutch are engaged with
teeth of output shaft.
4.Apply Loctite 290 to threads of bolts, fit bolts
noting that...

TRANSFER BOX
42
OVERHAUL
14.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
15.Fit differential lock detent ball and spring.
16.Apply Loctite 290 to threads of detent plug.
17.Fit and tighten detent plug then unscrew 2 full
turns.
18.Ensure’O’ring is correctly located on
differential lock selector housing.
19.Fit differential lock selector assembly ensuring
that selector finger is located in recess in
differential...

TRANSFER BOX
OVERHAUL43
All boxes
28.Up to serial no. 288709E:Apply grease to new
high/low selector housing gasket, position
gasket on front output housing.
29.From serial no. 288709E:Apply sealant, Part
No. STC 3254 to mating flange of high/low
selector housing.
30.Fit housing ensuring that high/low selector
finger is located in recess in high/low selector
shaft.
31.Fit 6 bolts and tighten to 25 Nm (18 lbf.ft).Intermediate gears
CAUTION: The spacer fitted must be of the
selective length, non-collapsible...

TRANSFER BOX
44
OVERHAUL
3.Fit bearing inner track’A’on to tool post
ofLRT-41-017and position intermediate gears
on to bearing’A.’
4.Fit bearing inner track’B’to intermediate
gears, apply finger pressure to bearing inner
tracks and rotate gears 5 to 10 turns to settle in
bearing rollers.
5.Attach a DTI to base ofLRT-41-017, zero
gauge on top of tool post and take 2
measurements at 180°of the step height
between the top of the tool post and the inner
track of the bearing, take an average of the 2
readings...

TRANSFER BOX
OVERHAUL45
11.Raise intermediate gears until dummy shaft
LRT-41-004can be inserted from front output
housing side of main casing.
12.Fit intermediate shaft, drift shaft into position
whilst at the same time expelling dummy shaft
LRT-41-004 .
CAUTION: Ensure’O’ring is not displaced
from main casing.
13.Remove wire from around intermediate gears.
14.Rotate intermediate shaft until retaining plate
can be located on flat on shaft.
15.Apply Loctite 290 to threads of retaining plate
bolt.
16.Fit...