Land Rover Range Rover 1987 Lt230 Transfer Box Rover Manual

							po;$ 1987LT230 TRANSFER GEARBOX
42.
I’
43.
44.Locate the rear differential bearing on to the
hub and press it into position using the
smaller end of tool 
18G1424.Fit the stake nut and tighten to the specified
torque usingtool 
18G1423 (see section
06-Torque values).
Check the end float of the high and low range
gears 0.05 to 0.15 mm (0.002 to 0.006 in).
. .1603M
45.NOTE: If the clearances vary from those
specified in the data, at the beginning of
the overhaul: the assembly must be rebuilt
using the relevant new parts.
Peen the stake nut collar by carefully forming
the collar of the nut into the slot as illustrated.
CAUTION: A round nose tool must be used for
this operation to avoid splitting the collar of the
nut.
ST1604M ,++-A46. Clean and check high/low selector fork
assembly for wear and replace if necessary.
Continued
21:.‘. 
						

							::,LT230 TRANSFER GEARBOX,’‘
						

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R”;;; 1987LT230 TRANSFER GEARBOX
Centre differential unit refit
I. Fit the selector fork/shaft assembly to the
high/low selector sleeve on the differential
assembly, with detent groove to the rear of
the differential assembly.
2. Locate the differential assembly complete with
selector fork into the transfer box casing. It
may be necessary to rotate the output shaft to
ease fitment, and guide selector shaft into its
hole.
3. Fit selector shaft ball and spring through the
side of the transfer box casing.
4. Apply Loctite 290 to detent plug; fit and
locate, by screwing gently fully home and then
unscrewing two turns.
.,Front output housing overhaul -dismantling
I. Unscrew seven retaining bolts and washers
and remove the differential lock selector side
cover and gasket, discard the gasket.
2. 
Unscr,ew three retaining bolts and washers and
lift the differential lock finger housing and
actuator assembly from the front output
housing.
3. Loosenthe locknut and unscrew the
differential lock warning light switch.
4. Remove selector shaft detent plug. spring and
ball using a suitable magnet.
5. Compress the selector fork spring and remove
the two spring retaining clips.
Continued 
						

							I -137 LT230 TRANSFER GEARBOX1987 ;;^d;;;
6.
7.
8.Withdraw the selector shaft from the rear of
the output housing.
Remove the selector fork and spring through
the side cover aperture.
Remove lock-up sleeve from the rear of the
output housing.
9.
10.Remove the output flange with oil seal shield.
11.
12.Using flange wrench 
18G1205 and socket
wrench, remove the flange nut, steel and felt
washers.
NOTE: Ensure that flange bolts are fully
engaged in the wrench.
NOTE: These parts need not be separated
unless the flange bolts are to be replaced.
Drive output shaft 
rearwards from housing
using a soft headed mallet.
Slide off the collar from the output shaft.
STlGlOM
13. Pry out and discard oil seal from output
housing using service tool 1861271.
14. Remove circlip with circlip pliers 
18G257.
15. Invert housing and drive out bearing from
inside the case as shown.
,_..’_.’
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24 
						

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ro;Eg 1987LT230 TRANSFER GEARBOX b 1
16.
,’.I’..”17.
18.
19.Drive out centre differential front taper roller
bearing track and shim.
Drive out selector shaft cup plug from
housing.
Clean all components ensuring all traces of
‘Loctitel are removed from faces and threads.
Examine components for wear or damage and
replace if necessary.
NOTE: Replace oil seal, felt seal and flange
nut.
.:,. . .,.
Re-assembling
20.21.
‘..I.
22.
23.
24.
25.Press the bearing into the housing; do not use
excessive force. To facilitate fitting the
beating, heat the front output housing. This is
not to exceed 100°C (212°F).
Using circlip pliers 
18G257, fit the bearing
retaining clips.
Pre-grease and fit a new oil seal (open side
inwards) using replacer tool 1861422, until the
seal just makes contact with the circlip.
Carefully coat the lips of the seal with clean
grease.
Slide collar on to the output shaft, with its
chamfered edge away from the dog teeth.
Fit the output shaft through the bearing and
drive home.
ST1614~Adjusting front differential bearing pre-load
26. Measure original differential front bearing track
shim.
27. Refit original shim into the output housing.
28. Drift differential front bearing track into the
housing using a soft driver.
ST1615M29. Grease and fit new gasket and locate the front
output housing on the transfer box casing.
Continued
iREVISED: DEC. 88
25
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LT230 TRANSFER GEARBOX
31.
32.
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							PO;;; 1987
LT230 TRANSFER GEARBOX [j7 141. Repeat the above operation for the rear
,
output flange.
ST1643M
42.43.
,T-.
44.
4.5.
,_:.:,.: :
ST161Compress the selector shaft spring and fit to
the selector fork.
Locate selector fork through front output
housing side cover aperture, ensuring that the
fork engages in the groove of the lock-up
sleeve.
Fit selector shaft through the aperture in the
front of the output housing and pass it
through the selector fork lugs and spring into
the rear part of the housing.
Rotate the selector shaft until the two flats for
the spring retaining caps are at right angles to
the side cover plate face.46. Compress the spring between the fork lugs
and slide the retaining caps on to the shaft
ensuring the spring is seated in the ‘cupped’
side of the caps.
47. Apply a suitable sealant, a new seal cup, and
drive the cup into position.
ST1644M
48.49.Fit selector shaft detent ball and spring in the
tapped hole on top of the output housing.
Apply Loctite 290 to detent plug threads.
Screw detent plug gently home and then
unscrew two turns.
49---@
48Continued
REVISED: APR. 8827 
” 
						

							.ILT230 TRANSFERGEARBOX
Differential lock finger housing
overhaul-dismantling
‘.‘.1.
2.
3.
4.Unscrew and discard the 
‘Nyloc’ nut and
remove the operating lever and washer.
Remove the pivot shalt from differential lock
finger housing.
Remove the 
‘0’ rings from the pivot shaft and
housing and discard.
Clean all components; examine for wear or
damage and replace if necessary.
Re-assembling
5.
6.
7.
8.Fit new 
‘0’ rings on to pivot shaft and lock
finger housing and lubricate with oil.
Locate the pivot shaft in the housing.
Fit the differential lock lever over the pivot
shaft so that the lever will point forward as
shown. This lever is then in the correct
operating position.
Retain the lever with a plain washer and new
‘Nyloc’ nut.
9.
10.Fit the differential lock finger housing into its
seating on the front output housing, ensuring
that the selector finger is located in the flat of
the selector shaft.
Apply Loctite 290 to the bolt threads and
retain the lock finger housing with the three
bolts and washers to the specified torque (see
section 
06-Torque values).
” ‘.High/low cross-shaft housing overhaul
1.
2.
7.
8.Release the locknut and remove the neutral
warning switch.
Remove the selector finger set screw and
withdraw the cross-shaft from the cross-shaft
housing and remove the selector finger.
Remove the 
‘0’ ring from the cross-shaft.
Drive out selector housing cup plug if
necessary.
Clean all the components and check for
damage or wear, replace if necessary.
Apply sealant to a new cup plug and fit so that
the cup is just below the chamfer for the
cross-shaft bore.
Fit new 
‘0’ ring to cross-shaft.
Lubricate the shaft and insert into the
cross-shaft housing.
Sll618M
j.REVISED: APR. 88 
						

							R”o”v’;l: 1987LT230 TRANSFER GEARBOX (37 I.:
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,
: ‘., ., :;:.:.,..a.9. Fit selector finger ensuring that it aligns with
the recess in the cross-shaft.
10.
11.
12.Apply Loctite 290 to the set screw and secure
the selector finger to the cross-shaft and fully
tighten to the specified torque (see section
OC-Torque values).
Grease and fit the high/low selector housing
gasket on the front output housing.
Fit high/low cross-shaft housing, ensuring that
the selector finger locates in the slot of the
selector shaft, and secure with six bolts and
washers to the specified torque (see section
06-Torque values).
Input gear overhaul-dismantling
Clean the input gear assembly and examine for
wear or damage. Remove the bearings only if
they are to be replaced.
Secure hand press MS47 in the vice and using
collars 
18G47-7 and button 18G47BB3, remove
rear taper roller bearing from input gear
assembly.
Invert input gear assembly in hand press and
remove front taper roller bearing.
Clean input gear.
Continued
REVISED: JUNE 8729 
						

							LT230 TRANSFER GEARBOX1987 KANbtROVER
Re-assembling
5. Position rear taper roller bearing on input gear
and using hand press MS47 and collars
18647-7 press the bearing fully home.
6. Invert input gear and fit the front taper roller
bearing using the press and collars.
J
IMS 47
;47-71 3
7. Prop up the transfer box casing on the bench
with the rear face uppermost.
8. Drive in the front taper bearing track.
309. Reposition transfer box casing so the front
face is uppermost and fit oil seal (open side
inwards) using replacer tool 
18G1422.
ST1622M )I10. Lubricate both 
bearings with clean oil.
11. Fit the input gear assembly into the transfer
box casing with the dog teeth uppermost.
REVISED: 
IUNE 87