Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

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46
OVERHAUL 25.From serial no. 288709E:Remove mainshaft
input gear bearing housing then apply sealant,
Part No. STC 3254 to main casing mating face
of bearing housing; position housing on main
casing ensuring that reference marks are
aligned. Fit and tighten 2 countersunk screws -
if fitted.
If fitted
26.Lubricate a new’O’ring with recommended oil
and fit to oil feed plate.
27.Fit oil feed plate ensuring that word TOP is
towards top of main casing and spigots are
located in cut-outs.
NOTE: If a replacement input gear having
a cross-drilled shaft is to be fitted, discard
oil feed plate and’O’ring.
All transfer boxes
28.Apply sealant, Part No. STC 3254 or position
new, dry gasket to mating face of cover
plate/power take-off cover. Position plate/cover
on bearing housing ensuring that reference
marks are aligned.
29.Position clip to stud nut.
30.Apply Loctite 290 to threads of bolts and stud
nut.
31.Fit 5 bolts and stud nut and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
NOTE: These bolts are threaded to head.Bottom cover
1.Up to serial no. 288709E:Position new bottom
cover gasket, dry on main casing.
2.From serial no. 288709E:Apply sealant, Part
No. STC 3254 to mating face of bottom cover.
3.Fit bottom cover.
4.Apply Loctite 290 to threads of bottom cover
securing bolts.
5.Fit bolts in positions shown and tighten by
diagonal selection to 25 Nm (18 lbf.ft).
NOTE: The remaining 4 bolts should not
be fitted at this stage as they are used to
attach support plate LRT-99-010 when
transfer box is refitted. 
						

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OVERHAUL47
High/low selector shaft detent
1.Fit detent ball and spring.
2.Apply Loctite 290 to threads of detent plug.
3.Fit and tighten plug then unscrew 2 full turns.
4.Operate high/low selector lever and check that
detent ball can be felt to positively engage and
disengage with grooves in selector shaft; screw
plug in or out until setting is correct.Interlock solenoid - if fitted
1.Position interlock solenoid in main casing.
2.Apply sealant, Part No. STC 3254 to mating
face of solenoid cover.
3.Fit solenoid cover and Belleville washer, fit
bolts and tighten to 10 Nm (8 lbf.ft). 
						

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48
OVERHAUL Neutral warning lamp switch - if fitted
1.Apply Hylosil PL32 sealant to threads of
switch.
2.Fit washer, fit and tighten switch to 25 Nm (18
lbf.ft).Differential lock warning lamp switch - adjust
NOTE: This procedure is only necessary
for switches fitted with a locknut.
1.Move differential lock selector fork to
differential locked position.
2.Connect a 12V test lamp and battery to
differential lock switch.
3.Screw switch in until test lamp is illuminated
then screw switch in a further 1/2 turn; tighten
locknut.
4.Disengage differential lock, check that test
lamp is extinguished.
5.Remove test lamp.
6.Up to serial no. 288709E:Apply grease to a
new gasket and fit to differential lock side
cover.
7.From serial no. 288709E:Apply sealant, Part
No. STC 3254 to mating face of differential lock
side cover.
8.Fit side cover.
9.Apply Loctite 290 to threads of side cover
bolts, fit bolts and tighten to 25 Nm (18 lbf.ft). 
						

							TRANSFER BOX
OVERHAUL49
Transmission brake
1.Apply sealant, Part No. STC 3254 to mating
face of rear output housing.
2.Position brake backplate on rear output
housing ensuring that alignment marks are
together.
3.Fit 4 bolts and tighten to 72 Nm (54 lbf.ft).
4.Fit transmission brake drum, fit countersunk
screw and tighten.
NOTE: Early transfer boxes - 2 screws are
fitted.
5.Tighten adjusting bolt to 25 Nm (18 lbf.ft) to
fully expand shoes against brake drum then
slacken adjusting bolt 1
1/2turns. Check that
drum is free to rotate. 
						

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DATA, TORQUE & TOOLS1
DATA
High/low selector finger width 15.90 to 15.95 mm..................0.625 to 0.627 in
High/low selector fork finger width 7.37 to 7.47 mm...............0.290 to 0.294 in
High/low selector shaft groove width 16.0 to 16.1 mm.............0.63 to 0.64 in
High/low selector hub groove width 7.5 to 7.6 mm..............0.295 to 0.30 in
Differential lock selector finger width 15.90 to 15.95 mm.............0.625 to 0.627 in
Differential lock selector shaft groove width 16.0 to 16.1 mm.......0.63 to 0.64 in
Differential lock selector fork finger width 7.92 to 7.9.........0.311 to 0.313 in
Differential lock selector spring free length 84.58 mm........3.33 in
Dog clutch selector fork groove width 8.05 to 8.20 mm............0.32 to 0.33 in
Differential front and rear half carrier gears load
to turn :
Used gears 0.45 kg............................... 1.0lb
New gears 1.72 kg................................ 3.8lb
Thrust washer thicknesses available 1.05 to 1.45 mm.............0.04 to 0.06 in
In increments of: 0.10 mm...........................0.004 in
Total load to turn - both sun gears fitted:
Used gears 0.90 kg............................... 2.0lb
New gears 3.44 kg................................ 7.6lb
Low range gear to high range hub clearance 0.05 to 0.15 mm......0.002 to 0.006 in
High range gear to high/low hub clearance 0.05 to 0.15 m........0.002 to 0.006 in
Mainshaft input gear bearing pre-load 0.05 mm............0.002 in
Mainshaft input gear bearing shim thicknesses
available 3.15 to 4.00 mm..................................0.12 to 0.16 in
In increments of: 0.05 mm...........................0.002 in
Differential bearing pre-load 0.05 mm...................0.002 in
Differential shim thicknesses available 2.00 to 3.25 mm...........0.08 to 0.13 in
In increments of 0.05 mm............................0.002 in
Transfer box gear train torque to turn 2.2 Nm............ 19lbf.in
Intermediate gear selective length
non-collapsible spacer sizes 58.325 to 50.300 mm...................2.296 to 2.235 in
In increments of 0.025 mm............................0.001 in 
						

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2
DATA, TORQUE & TOOLS TORQUE FIGURES
Drain plug 30 Nm................................. 22lbf.ft
Differential carrier bolts 60 Nm....................... 44lbf.ft
Differential bearing nut 72 Nm....................... 53lbf.ft
Differential lock selector lever nut 15 Nm............... 11lbf.ft
* Front output housing bolts 25 Nm.................... 18lbf.ft
* Rear output housing bolts 45 Nm.................... 33lbf.ft
*** Output flange nuts 162 Nm........................ 120lbf.ft
* Differential lock selector housing bolts 25 Nm.......... 18lbf.ft
High/low selector housing bolts 25 Nm................. 18lbf.ft
* Intermediate shaft retaining plate bolt 25 Nm........... 18lbf.ft
*** Intermediate shaft stake nut - Selective
length non-collapsible spacer 88 Nm.................. 65lbf.ft
* Bottom cover bolts 25 Nm......................... 18lbf.ft
* Bearing housing cover plate bolts and stud nut 25 Nm. . . 18 lbf.ft
Transmission brake backplate bolts 72 Nm............. 54lbf.ft
Interlock solenoid cover bolts - if fitted 10 Nm............ 8lbf.ft
** Neutral warning lamp switch 25 Nm................. 18lbf.ft
* Apply Loctite 290 to threads
** Apply Hylomar PL32 to threads
*** New nut must be fitted 
						

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DATA, TORQUE & TOOLS3
SERVICE TOOLS
LRT-37-11/2 Thrust button
LRT-37-014 Mainshaft oil seal replacer
LRT-41-001 Collars - differential rear bearing
LRT-41-001 Thrust button
LRT-41-002 Collars - differential front bearing
LRT-41-003 Mainshaft input gear bearing remover/replacer
LRT-41-004 Intermediate gear dummy shaft
LRT-41-005 Input gear mandrel
LRT-41-006 Intermediate gear bearing track replacer
LRT-41-007 Differential bearing nut remover/replacer
LRT-41-008 Differential bearing replacer
LRT-41-011 Output shaft bearing replacer
LRT-41-012 Output shaft oil seal replacer
LRT-41-014/1 Cross-bar
LRT-41-014/2 Depth block
LRT-41-014/3 Setting block
LRT-41-014/4 Pillar
LRT-41-017 Intermediate gear bearing pre-load measuring plate
LRT-51-003 Propeller shaft flange holding tool
LRT-51-009 Differential rear bearing track replacer
LRT-54-003 Differential front bearing track replacer
LRT-99-002 Hand press
LRT-99-003 Driver handle
LRT-99-006 Dial test indicator (DTI)