Land Rover Range Rover 1987 Lt230 Transfer Box Rover Manual

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yo;;; 1987LT230 TRANSFER GEARBOX I37 1Checking input gear bearing pre-load
19.
12. Secure bearing support plate in the vice. Drive
out input gear bearing track, and remove shim.
13.
14.
,...15.
16.17.
18.Clean bearing support plate and shim.
Measure original shim and note its thickness.
Fit the original shim to the support plate.
Locate the bearing track in the support plate
and press fully home.
Apply grease to the gasket and fit on to the
transfer box casing.
Fit the bearing support plate on to the transfer
box casing and secure with the six bolts, but
do not tighten.
Fit the service tool 
LSTl05 to input gear and
engage the spline.
20.
21.
22.
23.
24.
25.
26
27
28.REVISED: DEC. 88
31Tie a length of string to the cotter pin and fit
it to the service tool as shown.
Carefully tension the string using a spring
balance, little or no resistance will be felt at
this stage. Tighten the bolts a little at a time,
occasionally checking the rolling resistance.
With the bolts tightened to the specified
torque the rolling resistance should be 2.26 kg
to 9 kg (5 to 20 lb). NOTE: Alternatively using
a suitable torque wrench applied to the nut on
the service tool, a reading for a torque to turn
should be 0.56 to 
2.25Nm (5 to 20 in lb).If the reading obtained is outside the above
limits, the original shim must be changed.
Remove the spring balance, string and service
tool.
Remove the six bolts and the bearing support
plate.
Drive out the input gear bearing track from
the support plate and discard original shim.
Select the correct size shim to obtain a load
to turn of 
0.56-2.25Nm (5 to 20 in lb).Fit shim to support plate, locate bearing track
and press home.
Fit bearing support plate and secure to transfer
box casing with the six bolts but do not
tighten.
Repeat the rolling resistance check as
previously described,and note the value
obtained.
Continued
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							I371LT230 TRANSFER GEARBOX
Intermediate gear assembly overhaul
1. Drive out intermediate gear bearing tracks.
2. Remove circiips.6. Fit the ‘0’rings to the intermediate shaft and
into the intermediate shaft bore at the front ofthe transfer box casing.‘,,’
sTl62SMIntermediate gear re-assembly
3. Clean all intermediate gear components and
lock plate. Check for damage or wear and
replace as necessary.4. Fit new circlips into the intermediate gear
cluster.5. Using tools 
LST550-4 and MS550 fit bearing
tracks into the intermediate gear cluster.7. Check for damage to the intermediate shaft
thread and if necessary clean up with a fine
file or stone.
: ,
8. Lubricate the taper roller bearings and
intermediate gear shaft.
9. Insert new bearing spacer to gear assembly,
followed by the taper roller bearings.MS550
ST1630MST1 649M
10. Fit dummy shaft LST104 into the intermediate
gear cluster.
I 1. Locate the gear assembly into the transfer box
casing from the bottom cover aperture.REVISED: DEC. 88 
						

							FOE; 1987
LT230 TRANSFER GEARBOX (371
12. Insert intermediate shaft from the front of the
transfer box casing, pushing the dummy shaft
right through as shown and remove. (Making
sure that the intermediate gear cluster meshes
with the input gear and higher range and low
range gears).
13. Turn the intermediate shaft to allow fitting of
retaining plate.
14. Fit retaining plate and secure with retaining
bolt and washer.
15. Fit the intermediate gear shaft retaining stake
nut. Do not tighten at this stage.Adjusting intermediate gear torque-to-turn
16.
17.
18.
19.
20.Select neutral.
Fit service tool 
LSTIOS to input gear and
engage spline.
Tie a length of string to a cotter pin and fit to
the service tool as shown. Attach the spring
balance to the string.
To obtain the correct figures and to collapse
the spacer within the intermediate gear cluster,
tighten the intermediate shaft nut until the
load-to-turn has increased by 3.7 kg 
(7 lb) +1.63 kg 
(f 3 lb) on that noted when checking
input shaft load-to-turn.
Peen the stake nut by carefully forming the
collar of the nut into the intermediate shaft
recess, as illustrated.
CAUTION: A round nose tool must be used for
this operation to avoid splitting the collar of the
nut.
REVISED: DEC. 87Continued
33
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							LT230 TRANSFERGEARBOX
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Power take-off cover-reassemble
21. Clean power take-off cover and gasket face.
22. Fit the two countersunk screws and tighten to
the specified torque (see section 
06-Torquevalues).
23. Remove the six bolts from the bearing support
plate.24. Apply sealant to the cover plate gasket and fit
it to the bearing support plate.
25. Apply 
Lodite 290 to bolt threads and secure
the power take-off cover with the six bolts
and washers to the specified torque (see
section 
06-Torque values).
Bottom cover-reassemble26. Clean bottom cover and gasket face.
27. Apply sealant to cover gasket and fit to
transfer box casing.
28. Apply Loctite 
290 to bolt threads and secure
the bottom cover with six bolts and washers
to the specified torque (see section 
06-Torquevalues).Differential lock switch adjustment
1. Select differential locked position by moving
the differential lock lever towards the right
side of the transfer box casing.
2. Apply sealant to the differential lock warning
light switch and fit to the top of the front
output housing.
3. Connect a test lamp circuit to the differential
lock switch.
4. Screw in the lock switch until the bulb is
illuminated.
5. Turn in the switch another half a 
turn and
tighten with the locknut against the housing.
I+ -
3-
I
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ST1 634M-6. Disconnect the battery and move the
differential lock lever to the left to disengage
differential lock.
7. Clean the front output housing side cover.
8. Grease and fit side cover gasket.
9. Apply Loctite 290 to bolt thread& fit side
cover and secure with seven bolts and washers
to the specified torque 
(see se&n 06-Torquevalues).
REVISED: DEC. 87 
						

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R”$;f; 198711230 TRANSFER GEARBOX
Neutral warning switch adjustmentParking brake drum-reassemble
‘.1. Connect suitable test equipment as shown.
2. Fit the switch and neutral warning switch
locknut 
ensun, ,gcorrect setting for switch.
3. To attain the correct setting the following
procedure is applied:
4. Screw the switch in until test lamp 
I is
extinguished.
5. Screw in switch a further 
1/3 to l/2 turn.
6. Lock switch in position using locknut.
7. Select‘Low Range’ test lamp 1 should
illuminate. Select ‘High Range’ test lamp 2
should 
illumrnate. Select neutral both test
lamps should extinguish.1. Clean brake backplate and oil catcher and
apply sealant to the catcher joint face.
2. Locate brake backplate on the rear output
housing with the brake operating lever on the
right side of the transfer box casing.
3. Securethe backplate (including the oil
catcher) with the four special bolts and tighten
using a hexagonal socket to the specified
torque (see section 06-Torque values).
4. Clean and fit brake drum and secure with two
countersunk screws to the specified torque(see section 06-Torque values).
5. Adjust the parking brake. (Refer to Section 70
Brakes or Section 10 Maintenance).
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8. If adjustment is satisfactory remove the test
equipment.
c
‘,REVISED: JULY 88
35
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