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 retaining the
take-off cover
12. Remove the cover and gasket, discard the
gasket.8. Lift out the intermediate gear cluster anabearing assembly.
9. Remove the 
‘0’ rings from the intermediate
gear shaft and from inside the transfer box and
discard.
Continued 
						

							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 cross-shaft housing and gasket,
discard the gasket.Front 
output housingremoval
20. Remove the eight bolts and washers and
detach the output housing from the transfer
box casing, taking care not to mislay the
dowel. Remove the gasket and discard.
Centre differential removal
21. Remove high/low selector shaft detent plug,
spring and retrievethe ball with a suitable
magnet.
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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 plug. Discard the
washer.
ST1581M27. Drive out differential rear bearing track.
28. Clean all areas of the transfer casing ensuring
all traces of 
‘Loctite’ are removed from faces
and threads.
ST1582M
JContinued
REVISED: DEC. 87
13 
						

							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 overhaul-dismantling
1. Using flange wrench 
18G1205 and socket
wrench remove the flange nut, steel and felt
washers, Ensure flange bolts are fully engaged
in the wrench.
2. Remove output flange with circlip attached. If
necessary, use a two-legged puller.
NOTE: The circlip need only be released if
the flange bolts are to be replaced.
ST1583b.43. Remove speedo-drive housing. This can be
eased out with a screwdriver.
4.
5.Remove housing from the vice and drive out
the output shaft, by striking the flange end of
the shaft.
Carefully pry off the oil catch ring using a
screwdriver in the slot provided.
,:
.14
:.aREVISED: DEC. 87 
						

							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 and flange nut. Examine all other parts
for wear or damage and replace, if necessary.
ST1588MRe-assembling
13. Press output bearing into the housing. Do not
use excessive force. To facilitate fitting the
bearing, heat the output housing case. This is
not to exceed 100°C (212°F).
14. Retain bearing with circlip, using circlip pliers
18G257.Continued
15 
						

							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 position.
20.21.
22.Slide drive gear and spacer on to the output
shaft.
Locate output shaft into the bearing in the
housing and drive into position.
Locate speedometer gear (driven) housing
assembly into the output housing and press in
until flush with the housing face.
ST1540M
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.,:: .’‘..16.,”;:.’ :., ::. 
						

							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 and bush, taking
care not to disturb the high/low sleeve.
Mark-the relationship of the high/low sleeve to
the hub and then remove the sleeve.
Using a suitable press behind the low range
gear carefully remove the high/low hub and
low range gear.
7
ST1593MContinued
REVISED: APR. 8817 
‘,
,: 
						

							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.
Remove the rear lower bevel gear and thrust
washer from the rear part of the differential
unit.
Remove the rear differential unit from the vice
and clean all components.
2
3
2
ST1591,16. Inspect all components for damage or wear, fit
new components if necessary.
17. Using soft jaws secure the rear (longest half)
of the differential unit in the vice by gripping
the hub splines.
18. Lubricate and install the cross shafts and
pinion gears with new dished washers. DO
NOT fit the rear bevel gear at this stage. 
						

							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 gears. Tie a length of string around the
brake drum, attach a spring balance to the
string and carefully tension the string until a
load to turn is obtained. Alternatively use a
torque wrench applied to the brake drum
flange nut. Rotate the drum slowly by hand to
overcome initial load when using either
method. Note that illustration 
RR2332E shows
checking torque at rear bevel gear.NOTE: Gears that have been run will rotate
smoothly and will require a torque of 0.56 Nm (5
in 
lb). Equivalent force using spring balance: 0.45
kg 
(1 lb).New gears will rotate with a 
notchy feel and will
require a torque of not more than 2.26 Nm (20
in lb). Equivalent force using spring balance: 1.72
kg (3.8 
lb).Keep all components well lubricated when
carrying out these adjustments.
24.
25.
26.
27.
28.
29.Change the thrust washer for a thicker one if
the torque reading is too low. Five thrust
washers are available in 0.10 mm steps ranging
from 1.05 mm to 1.45 mm.
Dismantle the unit when the front bevel gear
thrust washer is selected.
Remove and retain the front bevel and thrust
washer combination.
Reassemble the unit with the rear bevel gear
and thinnest thrust washer in position.
Using soft jaws secure the front (shortest half)
of the differential unit in the vice by gripping
the hub splines.
Repeat the above procedure to obtain the
correct thrust washer for the rear bevel gear.
AR2332EREVISED: APR. 88
19Continued
4 
						

							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 the eight bolts to the specified
torque (see Section 06 
- Torque values).
Check the overall torque required to turn the
differential.This should be approximately
equal to the resistance of both bevel gears
added together.
Locate the front differential bearing onto the
front, upper differential shaft and press into
position using larger end of tool 
18C1424 as
shown.
37. Invert the differential unit and secure in the
vice.
NOTE: During the following sequences all
parts should be lubricated as they are
fitted.
18G 1424
38.
39.
40.
41.Fit the low range gear, with its dog teeth away
from the differential assembly.
Press the high/low hub on to the differential
splines.
Slide the high/low selector sleeve on to the
high/low hub ensuring that the alignment
marks are opposite each other.
Fit the bush into the high range gear so that
the flange is fitted on the opposite side of the
gear to the dog teeth. Slide the bushed gear
on to the differential assembly with the dog
teeth down.
. . .. .\..  .  
.
..‘7,.20
REVISED: APR. 88.: