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 carrier in a
soft-jawed vice.
19.Make suitable alignment marks between front
and rear halves of differential carrier.
20.Remove 8 bolts securing front half of carrier to
rear, remove carrier.
21.Suitably identify front sun gear to front half of
carrier, remove sun gear.
22.Remove and discard thrust washer.
23.Suitably identify each planet gear to its shaft
and fitted position of each cross shaft to rear
half of carrier.
24.Remove retaining ring.
25.Remove planet gears and cross shafts, remove
and discard dished thrust washers.
26.Suitably identify rear sun gear to rear half of
carrier, remove sun gear.
27.Remove and discard thrust washer. 
						

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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 any component found to be damaged.Intermediate gears and shaft
1.Check gear teeth for cracks, chipping and
uneven wear.
2.Check shaft for wear and threads for damage. 
						

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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 surfaces of cross shaft and
drilling in housing for wear.
2.Check core plug in housing for signs of
leakage or corrosion, apply Loctite 326 to
replacement plug.
3.Check high/low 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) 
						

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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 = 16.0 to 16.1 mm (0.63 to 0.64
in)
6.Check detent grooves in differential lock
selector shaft for wear.
7.Check differential lock detent ball for flat spots.
8.Check detent spring for distortion.
9.Check differential lock selector fork for cracks
and wear. 
						

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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 wear.
16.Check dog clutch teeth on shaft for wear and
damage. 
						

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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 filler plug, check threads for damage.
5.Fit but do not fully tighten filler plug.
6.Check that locating dowels are fitted in casing
and that blade of front output housing dowel is
positioned as shown.
7.Remove oil temperature switch - if fitted,
remove sealant from threads of switch and
main casing.
8.Apply Hylomar PL32 sealant to threads, fit and
tighten switch.
9.Check high/low detent ball for flat spots.
10.Check detent spring for distortion. 
						

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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
and damage.
5.Check teeth of high/low hub for cracks,
chipping and uneven wear.
6.Check selector fork groove width in high/low
hub:
Groove width = 7.5 to 7.6 mm (0.295 to 0.30 in)
7.Check splines and teeth of high/low selector
sleeve for uneven wear, cracks, damage and
chipping.
8.Check teeth of high and low range gears for
cracks, chipping and uneven wear.
9.Check high range gear bush for wear and
damage. 
						

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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 into rear half
carrier at this stage.
5.Fit retaining ring.
6.Fit a 1.05 mm (0.04 in) thick thrust washer to
front half carrier sun gear, position gear in front
half carrier.
NOTE: This is the thinnest of the thrust
washers available.7.Fit front half carrier to rear ensuring that
alignment marks are together.
8.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
9.Insert front output shaft into front half carrier,
check that gears rotate freely.
10.Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
11.Fit transmission brake drum to output flange,
secure drum using 2 nuts.
12.Secure a length of cord around brake drum,
attach one end of cord to a spring balance.
13.Tension cord and note load to turn figure
recorded on spring balance when brake drum
rotates.
NOTE: Used gears should rotate smoothly
whilst new gears will have a ’notchy’ feel
as they rotate.
14.Check figure obtained against specified load to
turn figure:
Used gears = 0.45 kg (1.0 lb)
New gears = 1.72 kg (3.8 lb)