Land Rover Range Rover 1987 Lt230 Transfer Box Rover Manual

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R”;;; 1987
LT230 TRANSFER GEARBOX [39 1
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LT230 TRANSFER BOX
The following operations can be carried out with
the gearbox in the vehicle. For ease of working, the
vehicle should be raised on a suitable hoist or
placed over a pit.
SPEEDOMETER DRIVE PINION
Remove and refit
Removing1. Disconnect the battery.
2. Raise the vehicle on a suitable hoist.
3. Remove the speedometer drive clamp and nut
and withdraw the cable.
4. 
Pry out the drive pinion assembly.
Refitting
5. Push in a new assembly and fit the
speedometer cable and secure with the clamp
and nut.REAR OUTPUT 
SHAFr OIL SEAL
Service tool:
18C1422-Mainshaft rear oil seal replacer
Remove and refit
Removing1. Disconnect the battery.
2. Raise the vehicle on a suitable hoist.
3. Disconnect the rear drive shaft from the
output flange and tie to one side of the
chassis.
4. Remove the brake drum retaining screws and
withdraw the drum.
5. Remove the four back plate bolts that also
retain the oil catcher and remove the brake
back plate and catcher.
NOTE: An hexagonal type socket should be
used for these bolts.
6. Remove the output shaft nut, steel washer, felt
washer and withdraw the flange.
7. Using the slot provided, lever off the dust
cover.
8. Pry out the output shaft oil seal(s).
..
i
,..I
: ,,..Refitting
9. Pre-grease between the seal lips. Insert the
double lipped oil seal, open side inwards,
using service tool 
18Gl422 until contact is
made with the bearing circlip. Take care not to
touch the seal lips while fitting.
10. Fit the dust cover.
11. Lubricate the surface of the flange which runs
in the seal and carefully fit the flange.
NOTE: To replace the flange bolts first
remove the circlip before fitting the flange.
12. Secure the flange with the nut and washer and
tighten to the specified torque (see section
06-Torque values).
13. Fit the back plate to the output housing using
the 4 bolts and plain washers.
NOTE: The two lower fixings also hold the
oil catcher which before fitting is coated
with a silicone rubber sealant on the mating
face.
14. Fit the brake drum and retain with the two
screws.
15. Reconnect the drive shaft and tighten to the
specified torque (see section 
OC-Torquevalues).
REVISED: JULY 88,: :: 
						

							LT230 TRANSFERGEARBOX
FRONT OUTPUT SHAFT OIL SEAL
Service tool:
18C1422-mainshaft rear oil seal replacer
Remove, refit and adjust
Removing
1.
2.
3.
4.
5.
6.Disconnect the batten/.
Raise the vehicle on a suitable hoist.
Disconnect the front drive shaft from the
flange and tie to one side of the chassis.
Remove the output shaft nut, steel washer, felt
washer and withdraw the flange.
Remove the oil seal shield.
Pry out the oil seal(s).Refitting
7.. 
j8.
9.
10.Pre-grease between the seal lips. Insert the
new double lipped oil seal, open side inwards,
using service tool 
18G1422 untit contact is
made with the bearing circlip. Take care not to
touch the seal lip while fitting.
Lubricate the running surface of the flange and
fit it together with the oil seal shield.
Secure the flange with the nut and washer and
tighten to the specified torque.
Refit the drive shaft and tighten to the
specified torque(see section 
06.Torquevalues).
TRANSFER BOX NEUTRAL WARNING SWITCH
Remove and refit
Removing
1.
2.
3.
4.
5.Disconnect the battery.
Raise the vehicle on a suitable hoist.
Disconnect the rear drive shaft from the
output flange and tie to one side of the
chassis.
Remove the brake drum retaining screws and
withdraw the drum.
Remove the four back plate bolts that also
retain the oil catcher and remove the brake
back plate and catcher.NOTE: An hexagonal type socket should be
used for these bolts.
6. Disconnect the four wiring connections to the
switch.
7. Loosen the lock nut using a suitable wrench
and unscrew the warning light switch.
Refitting and adjusting
8.
9.
10.
11.
12.NOTE: Adjust switch position ONLY with
transfer box neutral selected.
Connect suitable test equipment as shown.
Refit the switch and screw in until test lamp 1
is extinguished.
Screw in switch a further 
l/3 to l/2 turn.
Lock switch in position using the locknut.
Select‘Low Range’test lamp 1 should
illuminate. Select ‘High Range’ test lamp 2
should illuminate. Select neutral, both test
lamps should extinguish.
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I
13.
14.
15.
16.If adjustment is satisfactory, remove the test
equipment
andreconnectwiring leads
correctly and check operation of the audible
warning unit.
Fit the back plate to the output housing using
the 4 bolts and plain washers.
NOTE: The two lower fixings also hold the
oil catcher which before. fitting is coated
with a silicone rubber sealant on the mating
face.
Fit the brake drum and retain with the two
screws.
Reconnect the drive shaft and 
ti&hten to the
specified torque (see section 
06-Torquevalues).
‘..;.2REVISED: JULY 88 
						

							R”;$ 1987
LT230 TRANSFER GEARBOX ki? 1
LT230 TRANSFER GEARBOX
,
,Service tool: 
18G 1425 - Guide studs (3) Also,
locally manufactured adaptor plate, see below.
Remove and refit
Adaptor plate for removing transfer gearbox
The transfer gearbox should be removed from
underneath
thevehicle,using asuitable
transmission jack. An adaptor 
pla:e for locating the
transfer gearbox onto the jack can be manufactured
locally to the drawing 
RR2195E.WARNING: Where the use of a transmission
hoist is necessary, it is ABSOLUTELY ESSENTIAL
to follow the hoist manufacturer’s instructions to
ensure safe and effective use of the 
.equipment.
2s’s6-35 95 37
ARC WELD
0.35 09-
/I
32’ 30’MATERIAL: STEEL PLATE
*= TO BE DRILLED TO FIT TRANSMISSION JACK BEING USED
RR2195E
i
.L..>*.:Continued
REVISED: JULY 883 .”
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							.  ...: :1987 k”d;;iRemoving
11.
1.
2.
3.
4.
5.
6.
7.
.,8.,:.9.. . .‘(.:’Install the vehicle on a suitable hoist.
Open the hood.
Disconnect the battery.
Release the airflow meter to plenum chamber
hose.
Remove the four screws securing the glove
box liner to the glove box and lift out the
liner.
Carefully pry the window lift switch panel away
from the front of the glove box.
Identify
eachswitchconnectionfor
re-assembly, disconnect the plugs and remove
the switch panel.
Remove the main and transfer gearbox knobs.
Carefully pry the centre panel out of the floor
mounted console and remove it from the
vehicle.
‘::i10. Release the two bolts and two screws securing
the console assembly to the gearbox tunnel.
12.
13.
14.
15.
16.
17.Release the parking brake and remove the
cotter pin, 
clevis pin and washer securing the
parking brake cable to the parking brake lever.
Carefully maneuver the assembly away from
the radio housing and remove it from the
vehicle.
Release the large nut retaining the parking
brake outer cable to the top of the gearbox
tunnel.
Remove the nut and feed the cable through
the hole to the underside of the vehicle.
NOTE: The illustration for the following
removal instructions is located at the top of
the following page.
Raise the vehicle on the hoist and drain the
transfer gearbox.
Release the nut and clamp securing the
speedometer cable to the rear of the transfer
box.Withdraw the cable from the speedometer
drive pinion.
RRleelE15
18
19.Release the four nuts securing the rear drive
shaft to the rear output flange and tie to one
side of the chassis.
:.Remove the four nuts securing the front drive
shaft to the front output flange and tie to one
side of the chassis.
J
4
REVISED: JULY 88 
						

							LT230 TRANSFERGEARBOX27 37
18k---L------tnr”77 -1
2619
20.
21.
22.
23.
24.
25.
26.Release the bolts securing the intermediate
exhaust pipe to the centre catalyst and
separate the pipes. Retrieve the dougnut.Remove the clamp at the tailpipe bracket,
carefully tie the exhaust to the chassis side
member.Manufacture an adaptor plate in accordance
with the drawing, to attach to the transmissionjack and transfer box to facilitate removal
tRR2195E).Place four, 30mm (1.250 in) long spacers
between the top of the hoist and the adaptor
plate at the securing points and secure the
adaptor plate to the hoist.
Remove the four central bolts from the
transfer box bottom cover, move the jack into
position and secure the adaptor plate to the
transfer box.Adjust the jack to take the weight of the
transfer box.
Remove the tie bar from the transfer gearbox.
27.
28.
29.
30.
31.
32.
33.
34.
35.Remove the right-hand side mounting bracket
to chassis nuts and bolts.Remove the rear left-hand side mounting
bracket to chassis nuts and bolts.Remove right-hand side mounting bracket to
flexible mounting rubber retaining nut and
place bracket aside.
Lower the jack until the rear brake drum clears
the rear passenger footwell.Remove the cotter pin and washers securing
the differential lock lever to the connecting
rod, and disconnect the lever from the rod.
Disconnect the electrical leads from the
differential lock switch and neutral warning
switch.Remove the breather pipe from the top of the
transfer gearbox.
Select low range transfer box gear position.’Release the high/low rod lower lock nut and
remove the rod from the yoke.
JContinued
REVISED: JULY 885 :,’ 
						

							LT230 TRANSFER GEARBOX1987 wxNbcROVER
; ,(’36. Place a suitable wooden block between the
main gearbox and chassis cross-member, thenlower the jack until the gearbox contacts the
wooden block.37. Remove the upper and lower bolts securing
the transfer box to the main gearbox.38. Fit three guide studs to the main gearbox 
18C1425 and maneuver the transfer gearbox
rearwards to detach it from the main gearbox.Refitting
39. Make sure that the joint faces of the transfer
box and main gearbox extension case are
clean and that the three guide studs, 
18C
1425, are fitted to the extension case.40. Lubricate the oil seal in the joint face of
transfer box, secure the transfer box to the
adaptor plate on the lifting hoist and raise the
hoist until the transfer box can be located
over the guide studs.
41. Remove the guide studs and secure the
transfer box to the main gearbox extension
case. Tighten the nuts and bolts to the correct
torque (see section 06-Torque values).42. Complete the refitting procedure by reversing
the removal sequence, noting the following
important points.43. After removing the lifting hoist and adaptor
plate from the transfer box, clean the threads
of the four bolts for the transfer box bottom
cover, coat them with Loctite 290 and fit them
together with spring washers. Tighten to the
specified torque.44. Refill the transfer box with the correct grade
oil to the oil level plug hole. (See Section 09).
45. Check, and if necessary top-up the oil level in
the main gearbox. Use the correct grade oil.
(see section 09).46. Check the operation of the parking brake and
adjust as necessary. (see section 10).
6REVISED: JULY 88
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							RANGE
ROVER
LT230 TRANSFER GEARBOX 37r-l
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I I37 LT230 TRANSFER GEARBOXIXMIYUCROVER
8
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							1. Transfer box. Case assembly.
2. Power take-off assembly.
3. tntermediate gear assembly and bottom cover.1I
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CD 
						

							WMIYUC
LT230 TRANSFER GEARBOXROVER
LT230 TRANSFER GEARBOX OVERHAUL18G 1423
Service Tools:
18G 47-7-input gear cluster bearing cones
remover/replacer
18G 
4788-l-Adaptor centre differential bearing
remover
18C 
47BB-3 -Adaptor centre differential bearing
remover button
18C 257Kirclip pliers
18G 1205-Drive flange wrench
18G 1271
-Oil seal remover
18G 1422-Mainshaft rear oil seal replacer
18G 1424
MS 47
MS 550
LST 47-1
LST 104
LST 105
LST 
550-4-Adaptor/socket centre differential
locknut remover/replacer
-Centre differential bearing
replacer
-Hand press
-Bearing and oil seal replacer
handle
-Adaptor centre differential bearing
remover
-Intermediate gear dummy shaft
-Input gear mandrel
-Intermediate gear bearing races
replacer
TRANSFER BOX DATA
Front and rear bevel gear 
pre-load.............................See text
High range gear end-float..........................................0.05 to 0.15 mm (0.002 to 0.006 in)
Front differential bearing pre-load..............................0.56 to 1.69 Nm (S-15 in 
lb)Input Rear bearing pre-load.......................................
0.56 to 2.25 Nm (S-20 in 
lb)0.56 to 1.69 Nm (S-15 in lb)lniermediateshaftbearingpre-load. . . . . . . . . . . . . . . . . . .Parking brake removal
1.
2.Remove two countersunk screws and withdraw
brake drum.
Removefour bolts securing the brake
back-plate; the two bottom fixings retain the
oil catcher.
NOTE: An hexagonal type socket should be
used for these bolts.Bottom cover removal
3. Remove the six bolts and washers retaining
the bottom cover.
4. Remove the bottom cover and gasket, discard
the gasket.
ST1570M
10REVISED: DEC. 87