Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

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OVERHAUL
39.Remove plug securing high/low selector shaft
detent spring and ball.
40.Remove detent spring.
41.Remove ball using a stick magnet.
CAUTION: Suitably identify plug, detent
spring and ball to their fitted positions, do
not interchange with differential lock
selector shaft detent components.
If fitted
42.Remove 4 bolts securing interlock solenoid
cover, remove cover and Belleville washer.
43.Remove interlock solenoid.
44.Remove neutral warning lamp switch and
washer.
All transfer boxes
45.Withdraw differential assembly together with
high/low selector shaft and fork.COMPONENT DISMANTLING
High/low cross shaft housing
1.Loosen locknut and unscrew low detect switch
- if fitted.
2.Remove setscrew securing high/low selector
finger to cross shaft.
3.Withdraw cross shaft from housing, recover
high/low selector finger.
4.Remove and discard’O’ring. 
						

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Front output housing
1.Remove 7 bolts securing differential lock
selector side cover, remove cover.
2.Up to serial no. 288709E:Remove and
discard gasket.
3.Remove 3 bolts securing differential lock
selector housing, remove housing and selector
as an assembly.
4.Remove and discard’O’ring from selector
housing.
5.Remove plug securing differential lock detent
spring and ball.
6.Remove detent spring.
7.Remove ball using a stick magnet.
CAUTION: Suitably identify plug, detent
spring and ball to their fitted positions, do
not interchange with high/low selector
shaft detent components.
8.Compress differential lock selector fork spring
and remove retaining clip from each end of
spring.
9.Withdraw differential lock selector shaft from
front output housing, recover spring.
10.Remove differential lock selector fork. 
						

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OVERHAUL
11.Position propeller shaft flange holding tool
LRT-51-003to output shaft flange.
12.Remove and discard self-locking nut.
13.Remove and discard steel and felt washers.
14.Remove output shaft flange together with mud
shield.
NOTE: A replacement output flange will be
supplied together with new mud shield
and output shaft oil seal.
15.Using a mallet, drive output shaft out of front
output housing.
NOTE: If it is necessary to use a hand
press to remove output shaft, position
thrust button LRT-370-11/2 between shaft
and press mandrel.
16.Noting its fitted position, remove dog clutch
from output shaft.
17.Noting its fitted position, remove bearing
spacer from output shaft.
18.Taking care not to damage front output
housing, remove and discard output shaft oil
seal. 
						

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19.Using suitable circlip pliers, remove and
discard circlip retaining output shaft bearing.
20.Support front output housing on suitable blocks
of wood.
21.Using a soft metal drift, drive output shaft
bearing out of housing; discard bearing.
22.Invert front output housing.
23.Using a soft metal drift, drive differential
bearing track out of housing, discard bearing
track.
24.Remove selective shim. 
						

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OVERHAUL Rear output housing
1.Position propeller shaft flange holding tool
LRT-51-003to output shaft flange.
2.Remove and discard self-locking nut.
3.Remove and discard steel and felt washers.
4.Remove output shaft flange together with
circlip.
NOTE: A replacement output flange will be
supplied together with new output shaft
oil seal.
5.Carefully lever speedometer driven gear and
housing out of rear output housing.
6.Remove and discard’O’ring.
7.Withdraw speedometer driven gear from
housing, remove and discard oil seal from
housing. 
						

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8.Position rear output housing on bed of hand
press.
9.Position thrust buttonLRT-37-11/2between
end of output shaft and press mandrel.
10.Press output shaft out of housing.
11.Recover spacer and speedometer drive gear
from output shaft.
12.Using a screwdriver inserted in slot in rear
output housing, lever mud shield out of
housing.
CAUTION: Discard mud shield if it is
damaged.
13.Taking care not to damage rear output
housing, remove and discard output shaft oil
seal. 
						

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OVERHAUL
14.Using suitable circlip pliers, remove and
discard circlip retaining output shaft bearing.
15.Support rear output housing on suitable blocks
of wood.
16.Using a soft metal drift, drive output shaft
bearing out of housing; discard bearing.Main casing
1.Support main casing on suitable blocks of
wood.
2.Using a soft metal drift, drive differential rear
bearing track out of main casing; discard
bearing track.
3.Invert main casing.
4.Using a soft metal drift, drive mainshaft input
gear bearing track out of main casing; discard
bearing track. 
						

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Mainshaft input gear bearing housing
1.Secure mainshaft input gear bearing housing in
a soft-jawed vice.
2.Using a soft metal drift, drive input gear
bearing track out of housing; discard bearing
track.
3.Remove selective shim.Intermediate gears
1.Secure intermediate gears in a soft-jawed vice.
2.Using a soft metal drift, drive intermediate shaft
bearing track out of gears; discard bearing
track.
3.Remove and discard circlip.
4.Repeat above procedure for remaining bearing
track. 
						

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OVERHAUL Mainshaft input gear assembly
NOTE: Defender input gear illustrated.
1.Secure hand pressLRT-99-002in a vice.
2.Assemble collarsLRT-41-003around bearing
to be removed.
3.Position mainshaft in hand press, remove and
discard bearing.
4.Repeat above procedure for remaining
bearing.Differential lock selector
1.Remove and discard self-locking nut retaining
selector lever.
2.Remove washer and selector lever.
3.Withdraw selector finger and shaft from
housing.
4.Remove and discard’O’ring. 
						

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Differential
1.Secure differential in a soft-jawed vice.
2.Remove staking from bearing retaining nut.
3.Remove nut using toolLRT-41-007;discard
nut.4.Secure hand pressLRT-99-002in a vice.
5.Secure collarsLRT-41-001around rear
bearing.
NOTE: This bearing is adjacent to
threaded end of differential shaft.
6.Position differential in hand press with thrust
button, part of toolLRT-41-001between press
mandrel and differential shaft.
7.Press differential out of bearing.
CAUTION: Take care that differential does
not drop out of bearing.
8.Remove differential from press, discard
bearing.