Land Rover Defender 90 110 Workshop Book 3 Rover

							LT230T TRANSFER GEARBOX I37 I 
1. Install the vehicle on a ramp. 
2. Disconnect thc battery. 
3.  Remove  the cover  panel  from the right
-hand  seat 
4. Remove the breathcr pipe union  from the transfer 
5.  Disconnect  the 
high/low lever. 
base. 
gearbox 
high/low cross-shaft  housing.  16. 
Remove  three 
nuts and bolts  securing  the right- 
handgearbox  mounting bracket to the chassis, then 
remove  the 
nut from the rubber mounting  and 
withdraw  the bracket. 
17. Place  a suitable  wooden  block between  the indin 
gearbox and chassis  cross-member,  then lower  the 
hoist  until the gearbox  contacts  the wooden  block. 
18. Disconnect  the electrical  lead from thc differential 
lock  switch. 
19.  Move  the small  crank  lever, for 
the highhow 
selector,  upward to allow access  to the  adjacent nut 
20. 
21. 
22.  securing 
the transfer 
box to the main  gearbox 
extension  case. 
Remove 
the two  nuts  and four  bolts  securing  the 
transfer  box 
to the main gearbox  extension  case. 
Fit three guide  studs, 18G 1425, through the 
transfer  box bolt holes to support it during 
removal. 
Lower  the hoist  and withdraw  the transfer  box 
from  the vehicle. 
6. Disconnect  the transmission  brake cable at the 
7. Raise the vehicle  on the  ramp  and drain  the oil 
8. Remove  the centrc section of the  exhaust  system. 
9. Disconnect  the front and rear  propeller  shafts from 
the  gearbox  and move  them aside. 
10. Disconnect  the speedometer  cable from the 
transfer  gearbox. 
11. Remove  the split  pin at the  lower  end of the  pivot 
arm  for the  differential 
lock control.  Then, rcmove 
the two bolts securing  the pivot  arm to allow  the 
link to be  disconnected. 
12. Manufacture  an adaptor  plate in accordance  with 
the  drawing,  to attach 
to the  gearbox  hoist and 
transfer  box to facilitate  removal 
(RR244M). 
13. Place four, 30 mm (1.250 in) long  spacers  between 
the top ef the hoist  and the adapter p!ate at the 
securing  points and secure  the adaptor  plate to the 
hoist. 
14.  Remove  the four  central  bolts from  the transfer 
box  bottom  cover, move the hoist  into position  and 
secure  the adaptor  plate 
to the transfer  box. 
15.  Adjust  the hoist 
to take  the weight  of the  transfer 
box.  clevis 
joint. 
from  the transfer  box. 
. ,. .. .. 
, : ,. . .. .. 
Refitting 
23. Make  sure that the joint  faces  of the  transfer  box 
and  main  gearbox  extension  case are clean  and that 
the  three  guide  studs, 
18G 1425, arc fitted  to the 
extension  case. 
24. Lubricate the oil scal 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. 
25.  Remove  the guide  studs and secure  the transfer 
box  to the  main  gearbox  extension  case. Tighten 
the 
nuts and  bolts  to the corrcct torque. 
26.  Complete 
the refitting procedurc by reversing  the 
removal  sequence,  noting 
the iollowing important 
points. 
27.  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 
washers.  Tighten to the  correct  torque. 
the  oil 
level plug  hole. 
main  gearbox.  Use the correct  grade oil. 
as  necessary. 
\,xdjth Lectitc 290, 2nd fit them tegethcr with snrinu Y a b 
28.  Refill  the transfer  box with  the correct  grade oil to 
29. Check,  and if necessary  top up, the oil level in the 
30. 
Check the  operation  of the  handbrake and adjust 
87  
						

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37 
88 
LT230T TRANSFER BOX  
						

							LT230T TRANSFER BOX 
89  
						

							LT230T TRANSFER BOX 
90  
						

							LT230T TRANSFER BOX 
-_ *..., ,:”:!::. . LT230T TRANSFER GEARBOX OVERHAUL 8K.:;y.:., ,. ._ .;- .... Service Tools: 
18G47-7 - Input gear cluster  bearing  cones remover/ 
replacer 
18G47RB-1 - Adaptor  centre differential  bearing 
remover 
18G47BB-3 - Adaptor  centre differential  bearing 
remover  button 
18G257 - Circlip pliers 
18G1205 -Prop flange  wrench 
18G1271 -Oil seal remover 
37 
1861422 - Mainshaft  rear oil seal replacer 
1861423 
- Adaptor/socket centre  differential  stake nut 
remover/replacer 
18G 1424 - Centre  differential  bearing replacer 
MS47 
-Hand  press 
MS550 - Bearing  and oii seal  replacer  handle 
LST47
-1- Adaptor  centre differential  bearing remover 
LST104 -Intermediate  gear dummy  shaft 
LST105 - Input gear mandrel 
LST550-4 - Intermediate  gear bearing  replacer 
L 
TRANSFER  BOX DATA 
Front 
bevcl gcar end-float ......................... 
Rear  bevel  gear end-float .......................... 
Rcar output  housing  clearance ..................... 
High range  gear end-float ......................... 
Front differential  bearing prc-load .................. 
Input gear bearing  pre-load ........................ 
Intermediate  shaft bearing  pre-load ................. 
0,025 to 0,075 mm (0.001  to 0.003 in) 
0,025  to 0,075 mm (0.001 to 0.003  in) 
1,OO mm (0.039  in) 
0,05 to 0,15 mm (0.002 to 0.006  in) 
1.36  to 4.53 
kg (3 to 10 Ibs) 
2.26  to 6.80 
kg (5 to 15 Ibs) 
1.81 to 4.53 kg (4 to 10 Ibs) 
Transmission  brake removal (if not previously  Bottom cover removal 
removed) 
3. Rcmove  the six bolts  and washers  retaining thc 
4. Remove the gasket  and bottom  cover. 
1. Remove  two countersunk  screws and withdraw  bottom cover. 
2. Remove  four bolts  securing the brake  back-plate; 
brake 
drum. 
the  two  bottom 
fixing retain the oil catcher. 
NOTE:  An hexagonal  type socket  should  be used  for 
these  bolts. 
ST 
91  
						

							LT230r TRANSFER BOX 
Intermediate shaft and gear  cluster  removal 10. Remove  taper roller  bearings  and bearing  spacer 
from  the intermediate  gear cluster  assembly. 
5. Release  stake nut from recess in intermediate  shaft 
and  remove  stake nut and  discard. 
plate  at the  rear  face 
of the transfer  box. 
6. Unscrew  the single  bolt and remove  anti-rotation 
7.  Tap  the intermediate  gear shaft  from  the transfer 
box. 
10 ST1574M 
Power  take-of cover  removal 
11. Remove  six bolts  and washers  retaining  the take- 
12. Remove  the gasket  and cover. 
off 
cover  and speedo  cable clips. 
// f-- , 
Input  gear removal 
13. Remove the two countersunk  screws and detach 
the main  shaft bearing  housing. 
14. Remove  the gasket. 
15.  Withdraw 
the input  gear assembly. 
16. Prise out and  discard the oil seal  at the  front of the 
transfer  box casing  using service  tool 
1861271. 
17. Drift  out the input  gear front  bearing  track. 
8. Lift out the intermediate  gear cluster  and bearing 
9. Remove the ‘0’ rings  from the intermediate  gear 
assembly 
. 
shaft 
and from  inside  the transfer  box. 
$Ti 
x .J 
ST1576M - 
92  
						

							LT230T TRANSFER BOX 1371 
Highhow cross-shaft housing  removal 
18. Remove the six bolts  and washers  retaining  the 
19. Remove thc gasket and cross-shaft  housing. 
cross
-shaft 
housing  and earth  lead. 
- STI 577M 
Front  output  housing  removal 
20. Remove  the eight  bolts and washers  and detach the 
output  housing  from the transfer box casing,  taking 
care  not to mislay  the dowel. 
Centre  differential  removal 
21. Remove high/low selector shaft dctent  plug, spring 
and  retrieve  the ball  with 
a suitable  magnet. 
22. Withdraw  the centre  differential  and sclcctor shaft/ 
fork assembly. 
Rear  output  housing  removal 
23. Remove  six bolts  and washers  and dctach  the rear 
output  housing  and shaft  assembly 
from the 
transfer  casing. 
24. Remove  the gasket. 
Transfer  case overhaul - dismantling 
25. Remove  the studs  and dowels. 
26. Remove  the magnetic  drain plug and fi!ler!level 
ST1581M 
93  
						

							37 I LT230T TRANSFER BOX i 
27. Drift out differential rear bearing  track. 
28. Clean all areas of the  transfer  casing ensuring  all 
traces 
of “Loctite”  are removed  from faces  and 
threads. 
Transfer  case overhaul - re-assembling 
29. Fit studs  and dowels  to front  face of the transfer 
casing 
. 
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. 
30. Refit magnetic  drain plug with new copper  washer 
and  tighten 
to the specified  torque, loosely fit the 
filler/level plug. 
29 
Rear output housing  overhaul -dismantling 
1. Using - flange wrench 1861205 and socket  spanner, 
remove  the flange  nut, steel  and felt washers. 
Ensure  flange bolts are fully  engaged 
in the 
wrench. 
2. Remove  output flange with circlips  attached. If 
necessary,  use a two-legged  puller. 
NOTE:  The circlip  need  only  be released  if the 
flange  bolts are 
to be renewed. 
94 
3. Remove  speedo-drive housing.  This can be prised 
out  with  a screwdriver. 
4. Remove  housing from the vice  and drift  out the 
output  shaft, by striking  the flange 
cnd of the shaft. 
5. Carefully  prise off thc oil catch  ring using  a 
screwdriver 
in the  slot  provided. 
6. Prise  out and  discard  the seal  from  the output 
7. Using  circlip  pliers 18G2.57, rcmovc the circlip 
housing 
using 
tool 1SG1271. 
retaining  the bearing.  
						

							., 
ST1588M 
95  
						

							37 
20. Slide drive gear and spacer on to the output  shaft. 
21.  Locate  output shaft into the bearing  in 
the housing 
and  drift  into position. 
22.  Locate  speedometer  gcar (driven)  housing 
assembly  into the output  housing  and 
press in until 
flush  with 
the housing  face. 
LT230T TRANSFER BOX 
5. Remove  the high  range  gear and bush,  taking  care 
not  to disturb 
the high/low sleeve. 
6. Mark the  relationship  of the high/low sleeve to the 
hub  and then  remove  the sleeve. 
7. Using a suitable  press behind thc low range  gear 
carefully  remove the 
high/low hub and  low range 
gcar. 
- ST1640M 
Centre  differential unit overhaul -dismantling 
1. Secure  centre diffcrential  unit to a vice fitted  with 
soft  jaws,  and release  stake 
nut from recess. 
2.  Remove  stake nut using  tool 
1831423 and suitablc 
socket  wrench. 
3. Removc thc diffcrential  unit from the vice. 
ST1593M 
4. Secure  hand press MS47 in vice with collars 
18G47BB and using  button 1847BB/3 rcmove the 
rear  taper  bearing  and collars. 
ST1592M 
8. Substituting  collar LST47-1 remove front taper 
9. Remove  hand press  from the vice. 
vice  by gripping  the hub  splines. 
roller bearing. 
10. Using soft jaws  secure  the differential  unit in the 
STl596M \ll Y I 
96