Land Rover Range Rover 1987 Lt230 Transfer Box Rover Manual

KANbtROVER
LT230 TRANSFER GEARBOX I37 1
5.
“.intermediate shaft and gear cluster removal
Release stake nut from recess in intermediate
shaft, remove stake nut and discard.
Unscrewthe single bolt and remove
anti-rotation plate at the rear face of the
transfer box.
ST
ST157lM \/7. Tap the intermediate gear shaft from the
transfer box.
1’ .
and bearing
. 10. Remove the taper roller bearings
spacer from the intermediate gear cluster
assembly.
‘6Power take-off cover removal
11. Remove five bolts and washers...

KANbt
ROVERinput gear removal
13.
14.
15.
16.
17.Drive out the input gear front bearing track. Remove the two countersunk screws and
detach the main shaft bearing housing.
Remove the gasket and discard.
Withdraw the input gear assembly.
Pry out and discard the oil seal at the front of
the transfer box casing using service tool 
18C1271.
High/low cross-shaft housing removal
18.
‘,, ,’19.
,. :Remove the six bolts and washers retaining
the cross-shaft housing, ground lead and
retaining clip.
Remove the...

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I..A. . . .
:
::.-.’x‘. ..,
KANbt
ROVERLT230 TRANSFER GEARBOX22. Withdraw the centre differential and selector
shaft/fork assembly.
Rear output housing removal
23. Remove six bolts and washers and detach the
rear output housing and shaft assembly from
the transfer casing.
24. Remove the gasket and discard.
iTransfer case overhaul 
- dismantling
25. Inspect the studs and dowels for wear or
damage. Remove if replacements are required.
26. Remove the magnetic drain plug, copper
washerand filler/level...

l-l37 LT230 TRANSFER GEARBOX
KANLtROVER
,;. :’Transfer case overhaul 
- re-assembling
29.
30.
If previously removed, fit studs and dowels to
front face of the transfer casing. Use new
components where necessary.
NOTE: The position of the radial dowel
blade is set in line with the circle which is
formed by the front 
output housing fixing
holes.
Refit magnetic drain plug with new copper
washer and tighten to the specified torque,
loosely fit the filler/level plug.
ST1639MRear output housing...

KnlYut
ROVERLT230 TRANSFER GEARBOX
:.6. 
Pry out and discard the seal from the output
housing using tool 
18G1271.7. Using circlip pliers 
18G257, remove the circlip
retaining the bearing.
8. Drive out the bearing from the rear of the
housing.
ST1586M9. Remove speedometer gear (driven) from its
housing.
10. Remove the 
‘0’ ring and oil seal and discard.
fgi!-10
eJ9
10
+rjj11. 
Slide off spacer and speedometer drive gear
from output shaft.
12. Clean all parts, replace the 
‘0’ ring, oil seals,
felt seal...

l-l37 LT230 TRANSFER GEARBOX
KANCItROVER
15.Pre-grease between the seal lips and fit new
seal (open side inwards) using tool 
18G1422.The seal should just make contact with the
bearing circlip.
ST1588k1
16.Carefully coat the lips of the seal withclean
17.
16.
19.
ST1590Mgrease and refit oil catch ring onto output
housing.
Fit the 
‘0’ ring and oil seal (open side
inwards) to speedometer housing.
Lubricate the 
‘0’ ring and seal with oil.
Locate speedometer gear (driven) in housing
and press into...

PO;;; 1987LT230 TRANSFER GEARBOX
Centre differential unit overhaul -dismantling
1..’
2.
3.Secure centre differential unit to a vice fitted
with soft jaws,and release stake nut from
recess.
Remove stake nut using tool 18G1423 and
suitable socket wrench and discard stake nut.
Remove the differential unit from the vice.
18G 1423
. .
ST1591M4. Secure hand press MS47 in vice with collars
18C47BB-1 and using button 18C47BB13remove the rear taper bearing and collars.
ST1592M
5.
6.
7.Remove the high range gear...

LT230 TRANSFER GEARBOX1987 KANGtROVER
8. Substituting collar 
LST47-1 remove front taper
roller bearing.
9. Remove hand press from the vice.
IO. Using soft jaws secure the differential unit in
the vice by gripping the hub splines.
11.12.
13.
14.1s.
18REVISED: APR. 88 Remove the eight retaining bolts and lift off
the front part of the differential unit.
Release the retaining ring and remove front
upper bevel gear and thrust washer.
Remove the pinion gears and dished washers
along with the cross shafts....

LT230 TRANSFERGEARBOX
22.Lubricate and fit the front bevel gear and
thinnest thrust washer 
(FRC6956 1.05 mm).
Fit front half of the differential casing ensuring
that the two engraved arrows are aligned.
Fit securing bolts and tighten to the correct
torque (see section 06 
- Torque values).
Lubricate and insert the rear output shaft into
the bevel gear and check that the gears are
free to rotate.
20
24
I23. Fit the parkbrake drum to the output drive
flange and check the torque required to rotatethe...

l-l37 LT230 TRANSFER GEARBOX1987 K”d;;;Re-assembling
30. Fit the selected thrust washer and bevel gear
into the rear differential unit.
-34
,.‘.’31.
‘.
32.
33.
34.
35.
36.Assemble both pinion assemblies and dished
washers on to their respective shafts and fit
the rear differential unit. Secure the assemblies
with the retaining ring.
Lubricate all the components.
Fit the selected thrust washer and bevel gear
into the front upper differential unit.
Align both units as previously described and
secure with...