Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

							TRANSFER BOX
26
OVERHAUL 15.If load to turn figure is below that specified,
proceed as follows.
16.Remove front output shaft together with brake
drum.
17.Remove 8 bolts securing front half differential
carrier.
18.Remove front half differential carrier.
19.Remove front half carrier sun gear and thrust
washer.
20.Select a thicker thrust washer from the range
available.
NOTE: 5 thicknesses of thrust washers are
available rising in increments of 0.10 mm
(0.004 in) from 1.05 to 1.45 mm (0.04 to
0.06 in).
21.Position selected thrust washer and sun gear
in front half carrier.
22.Fit front half carrier to rear ensuring that
alignment marks are together.
23.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
24.Fit front output shaft and brake drum and
repeat load to turn check.
25.Repeat above procedures as necessary until
load to turn figure is as specified; record final
figure obtained.
26.Remove brake drum from front output shaft,
remove output shaft.
27.Remove bolts securing front half carrier.
28.Remove front half carrier, remove sun gear
and thrust washer.
CAUTION: Keep selected thrust washer
with sun gear.
29.Remove retaining ring.
30.Remove planet gears and cross shafts.
31.Fit a 1.05 mm (0.04 in) thick thrust washer to
rear half carrier sun gear, position gear in rear
half carrier.
32.Fit planet gears, cross shafts and dished thrust
washers in rear half carrier.
CAUTION: Ensure that planet gears are
fitted to their respective cross-shafts and
cross-shafts are fitted in their correct
location in half carrier.
33.Fit retaining ring.
34.Fit front half carrier to rear ensuring that
alignment marks are together.
CAUTION: Do not fit sun gear and thrust
washer into front half carrier.
35.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft). 
						

							TRANSFER BOX
OVERHAUL27
36.Invert assembly in vice and then insert rear
output shaft into rear half carrier, check that
gears rotate freely.
37.Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
38.Fit transmission brake drum to output flange,
secure with 2 nuts.
39.Carry out load to turn check using same
method as for front half carrier.
40.When load to turn figure is correct, record final
figure.
41.Upon completion, fit sun gear and selected
thrust washer to front half carrier.
42.Fit front half carrier ensuring that alignment
marks are together.
43.Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
44.With differential assembled, fit rear output shaft
and brake drum and check overall load to turn.
This should be approximately equal to total
load to turn figure of both front and rear half
carriers added together:
Used gears = 0.90 kg (2.0 lb)
New gears = 3.44 kg (7.6 lb)
45.Secure rear half carrier in a soft-jawed vice.
46.Fit a new front bearing using toolLRT-41-008. 
						

							TRANSFER BOX
28
OVERHAUL
47.Support front half carrier in a soft-jawed vice.
48.Fit low range gear ensuring that dog teeth on
gear are towards threaded end of shaft.
NOTE: Use a suitable hollow mandrel to fit
gear if it is tight on splines.
49.Fit high/low hub ensuring that alignment mark
made during dismantling is towards threaded
end of shaft.
50.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
51.Fit bush to high range gear ensuring that collar
on bush is on opposite side of gear to the dog
teeth.
52.Fit high range gear and bush ensuring that
collar on bush is towards threaded end of
shaft.
53.Fit a new rear bearing using toolLRT-41-008.
54.Fit a new bearing retainer nut, tighten to 72 Nm
(53 lbf.ft) using toolLRT-41-007.
CAUTION: Do not stake nut at this stage. 
						

							TRANSFER BOX
OVERHAUL29
55.Slide high/low selector sleeve and hub away
from low range gear.
56.Using feeler gauges, determine clearance
between low range gear and high/low hub:
Clearance = 0.05 to 0.15 mm (0.002 to 0.006
in)
57.If clearance is not as specified, fit a new low
range gear and high/low hub and re-check.58.Slide high/low selector sleeve and hub away
from high range gear.
59.Using feeler gauges, determine clearance
between high range gear and high/low hub:
Clearance = 0.05 to 0.15 mm (0.002 to 0.006
in)
60.If clearance is not as specified, fit new high
range gear and high/low hub and re-check.
61.Using a round nosed punch, stake collar of nut
into recess in differential shaft. 
						

							TRANSFER BOX
30
OVERHAUL Main casing
1.Fit a new differential rear bearing track using
toolLRT-51-009.
2.Using a straight edge and feeler gauges, check
that bearing track is recessed 1.0 mm (0.04 in)
below outer face of main casing.
3.Using a suitable mandrel, fit a new mainshaft
input gear bearing track.
CAUTION: Ensure bearing tracks are
seated squarely in recesses.4.Lubricate a new mainshaft oil seal with
recommended oil.
5.Invert main casing and fit oil seal, lip side
facing inwards, using toolLRT-37-014. 
						

							TRANSFER BOX
OVERHAUL31
Mainshaft input gear bearing housing
1.Ensure bearing track recess in housing is
clean.
2.Position a 3.15 mm (0.12 in) thick shim in
bearing housing.
NOTE: This is the the thinnest of the
shims available.
3.Using a suitable mandrel, fit new mainshaft
input gear bearing track.
CAUTION: Ensure bearing track is seated
squarely in recess.Mainshaft input gear assembly
1.Lubricate new bearings with recommended oil.
2.Secure hand pressLRT-99-002in a vice.
3.Position collarsLRT-41-003in hand press.
4.Position new bearing on collars.
NOTE: Smallest diameter of bearing must
be towards collars.
5.Locate end of mainshaft in bearing, press
mainshaft through bearing.
6.Repeat above procedure for remaining
bearing. 
						

							TRANSFER BOX
32
OVERHAUL Intermediate gears.
1.Lubricate new bearings and bearing tracks with
recommended oil.
2.Fit new circlips into intermediate gears.
CAUTION: Ensure that circlips are
correctly seated.
3.Fit new bearing outer tracks using tools
LRT-41-006andLRT-99-003.
CAUTION: Ensure bearing tracks are fully
seated against circlips.
4.Retain bearings with intermediate gears.Rear output housing
1.Heat rear output housing to 100°C (210°F).
2.Fit new output shaft bearing using tool
LRT-41-011.
3.Allow housing to air cool.
4.Fit new bearing retaining circlip ensuring it is
seated in groove. 
						

							TRANSFER BOX
OVERHAUL33
5.Lubricate a new output shaft oil seal with
recommended oil.
6.Fit oil seal using toolLRT-41-012.
NOTE: Use end of tool marked’REAR’to
fit oil seal.
7.Check that oil seal is just contacting circlip.
8.Slide speedometer drive gear and spacer on to
output shaft.
9.Position rear output housing on bed of hand
press.
10.Locate threaded end of output shaft in bearing.
11.Position thrust buttonLRT-37-11/2between
end of output shaft and press mandrel.
12.Press output shaft into bearing.
13.Fit mud shield with open face of shield towards
oil seal.
CAUTION: Do not fit output shaft flange at
this stage. 
						

							TRANSFER BOX
34
OVERHAUL
14.Fit speedometer driven gear into rear output
housing ensuring that gear teeth are engaged
with drive gear.
15.Lubricate a new’O’ring with recommended oil
and fit to driven gear housing.
16.Fit driven gear housing.
17.Lubricate a new oil seal with recommended oil,
fit seal with lip towards driven gear housing.Front output housing
CAUTION: Do not carry out assembly
operations until differential bearing
pre-load has been established- See
Differential bearing pre-load.
1.Heat front output housing to 100°C (210°F).
2.Fit new output shaft bearing using tool
LRT-41-011.
3.Allow housing to air cool.
4.Fit new bearing retaining circlip ensuring it is
fully seated in groove. 
						

							TRANSFER BOX
OVERHAUL35
5.Lubricate a new output shaft oil seal with
recommended oil.
6.Fit oil seal using toolLRT-41-012.
NOTE: Use end of tool marked’FRONT’to
fit oil seal.
7.Check that oil seal is just contacting circlip.
8.Position selected shim in front output housing.
9.Fit differential front bearing track using tool
LRT-54-003.
10.Fit bearing spacer to output shaft ensuring that
chamfer on spacer is towards threaded end of
shaft.
11.Fit dog clutch ensuring that flange on clutch is
towards splined end of shaft.
12.Using a mallet, drive output shaft into bearing.