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Land Rover 90 110 Workshop Rover Manual

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    							LT230R TRANSFER GEARBOX 
    ,,?:I:. ,. , :. . ,%a .. . ., .., 
    Front output  shaft housing - Overhaul 
    (Instructions 
    125 to 175) magnet. 
    Dismantling 
    124. Secure  the housing  in the  vice,  using  soft jaws. 
    125.  Remove  the seven  screws securing  the differential 
    lock  selector side covcr and  release 
    thc side cover 
    and  gasket. 
    126. Remove  the three  screws  securing  the differential  128. 
    Remove 
    the detent  plug  from  the top of the 
    housing  and 
    lift out the  spring  and  ball  using a 
    129. Compress  the selector fork spring  inside  the 
    130.  Slide  the sclcctor  shaft out 
    of the rear  of the 
    131. Remove the selector fork and spring through the 
    132.  Lift out dog sleeve  from the back of the output 
    .I,.. . .. I 
    housing  and slide  out the spring  locating C caps. 
    housing. 
    side  cover  aperture. 
    shaft housing. 
    flange  nut, steel  and 
    felt washers. A two-legged 
    puller  may be necessary. 
    NOTE:  Ensure that flange  bolts are fully  engaged 
    lock finger housing and lift Out the complete 133. Using the flange wrench 18G1205 remove [he assembly. 
    126 in the  wrench. 
    134.  Remove the output  shaft flange with oil seal 
    e9 
    shield. 
    ST1 I73M 
    127.  Slacken the  lock nut retaining the differential  lock 
    switch  and unscrew  the switch. 
    127, -1 d-- 128 / 
    NOTE:  These parts need not be separated  unless 
    the  flange 
    bolts are to be renewed. 
    135.  Drift the front  output  shaft  rearwards out of the 
    housing. 
    136.  Slide  off the  collar  from the 
    output shaft. 
    137.  Prise 
    out and  discard 
    thc oil seal(s), using  service 
    29  
    						
    							137 I LT230R TRANSFER GEARBOX 
    138. Using  circlip  pliers 186257 remove  the circlip. 
    139. 
    Remove  the housing  from the vice and  drift  out the 
    140.  Press  out 
    the differential  front  bearing  cup and 
    141.  Clean  all parts ensuring that  any traces 
    of Loctitc 
    142.  Renew  oil seals  and examine  all parts 
    for wear or 
    bearing  from inside. 
    remove 
    the shim  behind it. 
    are removed from  faces and threads. 
    damage,  renew as necessary. 
    Reassembling 
    143.  Press  the  front  bearing into the  housing. Do not 
    use  excessive  force, 
    if necessary, warm the 
    housing assembly  and case. 
    144. 
    Fit the  bearing retaining circlip,  using circlip pliers 
    186257. 
    145. 
    Fit a  new  dual  lip oil seal (open  side inward)  until 
    the  seal  is 
    in contact  with the bearing  circlip. It is 
    essential 
    to use  replacer  tool 1861422. 
    NOTE: On early  production  two separate  seals 
    were  used,  these should  be replaced  with the new 
    dual  lip seal. 
    - -- STSOSM 
    146.  Carefully  charge the lips  of the  seal  with  grease. 
    147.  Slide the  collar onto the front  of the  output  shaft 
    148.  Fit 
    the output  shaft through  the back of the 
    149.  Examine  the flange  seal  track  to check  for  any 
    with  its 
    chamfered  edge 
    to the front. 
    housing. 
    damage that  may harm  the seal. 
    Obtaining  bearing pre-load 
    150. Measure  the original  differential  front  bearing 
    151. Refit the original  shim. 
    152. Drift the  differential  front bearing  track  into the 
    housing. 
    153.  Grease  and 
    fit a new gasket  and  locate the front 
    output  shaft housing  on the  transfer  box. 
    154.  Loosely  retain the 
    h. ,sing with the eight securing 
    bolts  (with  spring 
    w,~ ners),  the upper  middle bolt 
    is  longer. 
    Do not i:illy tighten  the bolts  at this 
    stage.  track 
    shim,  noting  its thickness. 
    30 
    155.  Engage  high or low gear. 
    156. Check the rolling  resistance  of the  differential, 
    using  a spring balance  and a piece 
    of string  wound 
    around  the  exposed  splines 
    on the high/low hub. 
    Little 
    or no resistance will  register. 
    157. Tighten  the bolts  a little  at a  time,  occasionally 
    checking  the rolling  resistance.  With the correct 
    shim  selected  and 
    the bolts  tightened to thc 
    specified torque a pull of 1,s to 4,5 Kg (4 to 10 Ib) 
    is  required  on the  spring  balance.  This applies  to 
    new 
    or used bearings. 
    158.  If the  reading  is outside  the 
    abovc limits remove 
    the  front  output  shaft housing  assembly  from  the 
    transfer  case. 
    159. Using a suitable  extractor,  withdraw the front 
    differential  bearing  cup from  the  housing and 
    exchange  the shim  for one  of suitable  thickness. 
    160.  Rcfit  the bearing  cup. 
    161. Having  obtained  the  corrcct  rolling  resistance 
    prop
    -up  the  transfer  box on the bench with thc 
    front  sidc uppermost. 
    162.  Grease  and 
    fit the  front  output shatt housing 
    gasket  and locate  the housing 
    on the transfer  box. 
    163.  Apply  Loctite  290 to the  threads  of the  housing 
    securing  bolts and 
    fit the eight  securing bolts (with 
    spring washers).  Note that  the  upper middle  bolt 
    is  longer. 
    164. 
    Turn the  transfer  box into its  normal operating 
    position. 
    165. 
    Fit both  input  and output  flanges as  follows. 
    166. Using  flange  wrench 18G1205 and a torque 
    wrench 
    pull up  output  shaft to corrcct  position. 
    Check  that  the 
    oil seal shield  does not foul the 
    housing 
    . 
    NOTE: Ensure  that flange  bolts are fully  engaged 
    in the wrench.  
    						
    							LT230R TRANSFER GEARBOX 1371 
    167.  Slide the  dog sleeve onto the  rear of the output 
    shaft  ensuring that  the selector groove  in 
    thc dog 
    sleeve  is to  the  front. 
    168.  Compress  the differential  lock selector  shaft 
    spring, and 
    fit it between the sclcctor fork lugs. 
    169.  Locate  the  selector  fork  inside the side  cover 
    aperture 
    in the  housing  engaging  the groove in the 
    dog  sleeve  on the  output  shaft. 
    170. 
    Fit the  differential  lock selector  shaft into the 
    housing  from 
    the back,  grooved  (detents)  end 
    last,  and pass 
    it through the selector  fork lugs and 
    spring  and into  the front  of the  housing. 
    171.  Rotate  the  selector shaft until  the  two flats  are 
    uppermost. 
    172.  Compress 
    the spring  slightly between the fork lugs 
    and fit the two locating  ‘C’ caps. 
    17.5 & 
    173. Fit the selector shaft  detent ball and spring via the 
    tapped  hole  in the  top  of the housing. 
    174.  Apply  Loctite  290 
    to the  detent  plug threads, 
    screw 
    in the  detent  plug until  the spring  is just  coil 
    bound,  then back 
    off two complete  turns. 
    175.  Loosely 
    fit the differential  lock  switch in the 
    tapped hole on top  of the  housing,  leaving the 
    locknut  loose  for adjustment. 
    176.  Grease  and 
    fit the differential  lock selector  side 
    cover 
    gasket and fit the  side  cover,  securing it with 
    the seven  bolts (with spring washers). 
    Differential  lock finger  housing - Overhaul 
    (Instructions 
    177 to 183) 
    Dismantling 
    177. Remove  and discard thc Nyloc nut and release  the 
    lock  lever  and selector  ‘finger’ from the ‘finger’ 
    housing. 
    178.  Remove  and  discard the 
    ‘0’ rings from  the 
    selector  finger and the selector  finger housing. 
    179.  Clean  remaining  parts, examine  for wear 
    or 
    damage,  renew as  necessary. 
    STll79M 
    Reassem bly 
    180. Fit new ‘0’ rings to the finger  housing  and 
    selector  finger and lubricate  with oil. 
    181.  Locate the selector finger 
    in thc finger  housing. 
    182.  Fit  the differential  lock lever  over the flats 
    on the 
    selector  finger 
    so that it will face  forward in the 
    operating position. 
    183. Fit the plain  washer  and a ncw Nyloc  nut. 
    184. Fit the differential  lock  ‘finger’ housing  assembly 
    into  the  round  aperture 
    in the front  output  shaft 
    housing locating 
    the selector  ‘finger’ on the flat on 
    the selector shaft  inside the housing. 
    185.  Apply  Loctite  290 
    to the ‘finger’  housing  screw 
    threads  and 
    fit the three securing  screws (with 
    spring washers)  to 
    the correct torque. 
    186.  Grease  and 
    fit the differential  lock selector  side 
    cover gasket  and fit the  side cover,  securing it 
    with 
    the seven bolts  (with spring  washers). 
    187. Using a screwdriver  inside the housing  move the 
    high/low selector  shaft  rearwards (i.e. into high 
    range  position)  to provide  access 
    for fitting the 
    yoke over the end of the selector shaft. 
    188. Locate the yoke  on the  selector  shaft,  apply 
    iociiie 290 to the yoke set screw and fit iitc screw 
    to the specified  torque. 
    31  
    						
    							LT230R TRANSFER GEARBOX 
    208 192,199  194,198 191.197 
    Highllow selector housing - Overhaul 
    (Instructions 
    189 to 205) 
    Dismantling 
    189.  Remove the selector  fork grub screw completely. 
    190. Rcmove  the cross  shaft retaining circlip. 
    191.  Withdraw 
    the cross  shaft from the  selector 
    housing 
    with the  operating  arm attached. 
    192.  Lift  out 
    thc sclcctor fork from  the housing. 
    193.  Remove the  two 
    ‘0’ rings from the cross  shaft. 
    194.  Remove the operating arm  from the cross  shaft by 
    rcmoving the retaining set scrcw. 
    195. Clean  parts  ensuring that all traces of Loctite  are 
    removed,  examine  for  wear or damage,  renew  as 
    necessary. 
    Reassembling 
    106. Fit the ‘0’ ring  to the  operating  arm end of the 
    197.  Locate operating arm 
    on the shaft  blind hole. 
    198. Apply  Loctite  290 to the operating  arm  set scrcw 
    199. Locate the selector  fork inside  the housing. 
    200.  Slidc  the  cross  shaft into the housing  passing  it 
    through  the selector  fork. 
    201. 
    Fit thc ‘0’ ring to the  fork  end of the cross  shaft 
    (inside 
    the housing)  and lubricate  both ‘0’ rings. 
    202.  Position  the cross  shaft fully home. 
    203.  Locate 
    the selector fork 
    on the  shaft  blind  hole. 
    204.  Apply  Loctite  290 
    to the fork  grub  screw  threads 
    and 
    fit the grub  screw. 
    205. 
    Fit the  circlip  on the  end of the cross shaft. 
    206.  Grease  and 
    fit the gasket to the highhow selector 
    housing  aperture  on 
    the front output  shaft 
    housing. 
    207.  Position  the 
    highhow selector  housing so that the 
    projecting  selector fork engages  the yoke  side pins 
    inside the housing. 
    208.  Fit the  six selector  housing  retaining  bolts (with 
    spring  washers). 
    209. 
    Prop  up the  transfer  box  on the  bench  with  front 
    side  uppermost. 
    32 
    cross  shaft. 
    threads  and 
    fit the set screw.  210. 
    Fit the  oil seal  into 
    the front of the transfer box 
    (seal  lip to rear  of case)  using  replacer  tool 
    18G 1422. 
    211. Prop up the  transfer box on  the  bench  with  rear 
    side uppermost. 
    212.  Drift in the  input  gear front  bcaring  track  from 
    inside  the back  of the  transfer  box, using  a 
    suitable  punch. 
    Input gear - Overhaul 
    (Instructions 
    231 to 237) 
    Dismantling 
    213.  Clean  all parts,  examine for wear  and damage, 
    renew  as  necessary.  Remove  the bearings only 
    if 
    they are to be renewed. 
    214. 
    Secure  hand  press MS47 in vice and  using  collars 
    and buttons 
    18647-7 remove  the front taper roller 
    bearing  from the input  gear assembly. 
    215.  Reverse  input gear assembly 
    in hand  press  and 
    rcmove the rear taper roller bearing. 
    216. 
    Remove  the hand  press from the vice. 
    ST1184M II I 
    Reassem  bly 
    217. Locate thc front  taper  roller  bearing  on the input 
    - ;;” 
    gear assembly  and press  the bearing  fully home.  
    						
    							LT230R TRANSFER GEARBOX (371 
    c,+::,i3 *.rr:-. 218. Repeat  above  procedure and fit the rear taper 
    pzq roller  bearing. 
    219.  Lubricate  both bearings 
    with oil. 
    220. 
    Fit input  gear assembly into  the transfer  box from 
    the rear  (gear  end first). 
    Obtaining  bearing pre-load - with intermediate gear 
    cluster  removed 
    221. Secure  the mainshaft  bearing housing  in the  vice. 
    222.  Press  out  the rear input gear bearing  cup  and 
    223.  Clean  the main  bearing  housing  and measure 
    224. 
    Fit the  original shim  to the  main  bearing housing. 
    225.  Locate 
    the rear bearing  cup  on the  main  bearing 
    226.  Apply  grease  to the  gasket  and 
    fit onto the 
    2
    -27. Fit the  main  bearing  housing  and  tighten the two 
    remove 
    the shim  behind 
    it. 
    original  shim, noting  its thickness. 
    housing  and press 
    it fully home. 
    t ransfcr  box casing . 
    securing screws to the specified  torque. 
    - .. ; Y!!:!. .. . ., .. I ... . , . 1. 
    i. .. .I . , .,... . ... . .I. . ... 
    228. Wind sllfficienr striflg around the gear !W!h (0 
    rotate the input  gear. A pull  of  1,4 to 3,6 Kg (3 to 
    8 Ib) is required  on  the  spring balance.  This 
    applies  to new 
    or used  bearings.  229. 
    If the  reading  obtained is outside  the  above 
    limits  the original  shim  must be changed 
    accordingly. 
    230.  Remove 
    the two screws  retaining  the mainshaft 
    bearing housing. 
    231.  Press  out the rear  bearing  cup from  the  bearing 
    housing  and remove  and discard 
    the original  shim. 
    232.  Select  a shim 
    to the  required  thickness  to obtain 
    the correct  pre-load of 0,02 to 0,07 mm (0.001 to 
    0.003  in) on reassembly. 
    233. 
    Fit the shim  to the  main  bearing  housing and then 
    press the  rear bearing  cup into  position. 
    234. 
    Fit the  main  bearing  housing  and tighten  the  two 
    securing screws 
    to the  specified  torque. 
    235.  Grease  and 
    fit P.T.O.  cover gasket  and  finally fit 
    the P.T.O.  cover securing it with six bolts  (with 
    plain  washers) 
    to the specified  torque. 
    Intermediate gear  assembly - Keassembly 
    236.  First I-emovc the needle  roller bearings and  spacer 
    from  the gcar assembly. 
    237.  Clean  the parts,  including  the thrust  washers  and 
    lock  plate  and examine  for  wear 
    or damage, 
    renew  as  necessary.  Refer to DATA  at end 
    of 
    section for thrust  washer  thickness. 
    238. 
    Fit the 0 ring  to the intermediate  shaft. 
    239. 
    Fit the 0 ring  into the front  of the transfer case. 
    240.  Lubricate  thrust  washers,  bearings, shaft and 
    241.  Fit  needle bearings  with spacer  interposed. 
    spacer. 
    If  the bearings  have plastic cages,  the flangcd 
    cnd 
    of each  cage must face  the thrust  washers,  when 
    fitted. 
    242. 
    Fit front  thrust  washer  to slot  in transfer  (plain 
    side  to case). 
    243.  Locate  gear assembly  partially 
    into the  transfer 
    case 
    so that it rests  on the  front thrust  washer. 
    244.  Locate  rear thrust  washer  (plain side uppermost) 
    into  slot in transfer  case. 
    245.  Gently push  gear assembly into  mesh. 
    246.  Using  a screwdriver  through  the  intermediate 
    shaft  hole guide  the locating  tab on the  rear thrust 
    washer into the slot  provided 
    in the transfer  case. 
    247.  Align  gear and thrust  assembly  and slide  the 
    intermediate  shaft into  the  transfer box  from  the 
    rear. 
    248. Align  the  shaft so that  the  lock plate  slot in the 
    end is on top. 
    ?. ./ .I.... . .. . ,. .?, . NOTE: The  pre-load  can only  be measured  while 
    the  Transfer  gearbox 
    is separated  from the main 
    gear 
    box.  
    						
    							El LT230R TRANSFER GEARBOX 
    249. Apply  Loctite  290 to the  lock  plate  bolt threads. 
    Locate  lock plate 
    into position  and fit securing 
    bolt  (with  spring  washer). 
    250.
    - Using  a screwdriver  via the  bottom  of the transfer 
    case 
    lift up  the  gear  assembly  and measure  the 
    end
    -float  with feeler  gauges.  This  should  be 
    between 
    0,08 and 0,35 mm (0.003  and 0.014  in). 
    251.  Grease  and 
    fit the bottom cwer gasket. 
    252.  Apply  Loctite  290 
    to the ten bottom  cover  fixing 
    253. Clean and fit the bottom cover,  using the ten bolts 
    bolts 
    only. 
    (with  spring washers). 
    Transmission  brake assembly 
    254. Clean  brake backplate  and oil drip  plate  and 
    apply  silicone  rubber sealant.  Locate  the 
    backpiate on the rear  output shairispeedometer 
    housing so that the brake operating  lever is on the 
    right
    -side  rear. 
    255. 
    Fit the  four  Brako  Durlok  bolts, the lower  two 
    with plain washers,  also  retain the oil drip  plate. 
    Tighten 
    to specified  torque. 
    256.  Clean  and 
    fit brake  drum  and fit the two 
    countersunk  retaining screws. 
    34 
    257,261 259 258-   I 
    Highhow gear  change  housing - Overhaul 
    (Instructions 
    262 to 298) 
    Dismantling 
    262.  Remove  the split  pin from  the clevis pin  at the  top 
    of  the  differential  lock cross  shaft lever  which 
    secures  it 
    to the gear change  cross shaft. 
    263.  Remove  the  washer and clevis  pin and  the 
    anti- 
    rattle  nylon  strip. 
    264.  Mark  the  position  of the 
    high/low gcar  change 
    operating  arm on the  splined  shaft of 
    the gcar 
    change  crank arm. 
    265.  Slacken  the clamp  bolt and remove  the operating 
    arm. 
    266.  Remove  the  four bolts from  the  top  of the  gear 
    change  housing  and 
    iift off the grommet piate 
    grommet,  gate plate and gasket. 
    267.  Remove the  split pin from 
    the gear  change  crank 
    arm  clevis pin  and remove  the clevis  pin. 
    268.  Remove the  circlip from 
    the highilow gear change 
    lever bush. 
    269.  Withdraw the gear change lever  from the housing, 
    with  ball  and 
    socket bush. 
    Differential  lock switch  adjustment 
    257. Select  differential  locked  position by moving  the 
    differential  lock lever  towards  the right  side of the 
    transfer  box. 
    258.  Obtain a battery  and connect 
    a test  lamp circuit  to 
    the  differential  lock switch. 
    259. Slacken  the lock  nut  off  and screw in the lock 
    switch 
    until the  bulb  is illuminated. 
    260.  Turn  the lock switch  another half  turn 
    and tighten 
    the  lock  nut against 
    the housing. 
    261.  Disconnect 
    the battery  and move  the differential 
    lock  lever  towards  the left  side  of the transfer  box 
    to disengage the differential lock.  
    						
    							LT230R TRANSFER GEARBOX 
    .- .. c. ::.. I I .. ... I,: .~ .. ... 
    270. Rcmove  the two  countersunk  screws from the 
    271. Remove  the housing  end cover. 
    272. Remove  the two ‘0’ rings from  the end  cover. 
    273.  Remove 
    the cross  shaft from the housing. 
    274.  Compress 
    the detent  spring and  remove the gcar 
    change 
    arm from inside  the housing. 
    housing 
    end cover. 
    Reassem biy 
    279. Fit the two ‘0’ rings  to the  housing  end cover. 
    280. 
    Fit the  two ‘0’ rings  to the gear change  crank arm. 
    281.  Lubricate 
    ‘0’ rings with oil. 
    282.  Clip  the detent  spring onto the detent  plate. 
    283.  Fit detent  plate  assembly into housing  and retain 
    from  outside  with two Nyloc  nuts 
    (with plain 
    washers). 
    284.  Compress 
    thc detent  spring and fit the  gear 
    change crank  arm 
    in the housing. 
    285. 
    Fit cross  shaft  into  position  locating  end in the 
    crank  arm. 
    286.  Fit  the housing  end cover  to support the other  end 
    of  the  cross  shaft. 
    287.  Finally  secure the  housing end cover  with the two 
    countersunk  screws. 
    288.  Before  refitting  the gear  change  lever remove  the 
    clevis  pin bushes  and  the Nylon  socket  bush  and 
    ball. 
    289.  Clean all parts,  examine  for wear or damage, 
    renew as necessary. 
    290. Fit  and  grease  gear lever  ball and  Nylon  socket 
    bush  to gear  lever. 
    291.  Fit and  grease  clcvis pin bushes. 
    292.  Locatc  gear change  lever assembly 
    in cross  shaft 
    (do  not 
    fit socket  bush  retaining  circlip at this 
    stage). 
    293.  Align  gear change  lever  end with  crank  arm fork 
    ensuring 
    that the  gear  lever  is crankcd rcarwards 
    and fit clcvis and split  pin. 
    294.  Finally  secure Nylon socket  bush with circlip. 
    295.  Grease  and 
    fit gasket to gear change  housing face. 
    296. 
    Fit the gate plate. 
    297.  Fit the grommet. 
    298. 
    Fit the  grommet  plate  and  retain with the  four 
    securing bolts (with  spring washers). 
    275.  Remove 
    the two ‘0’ rings  from  the crank arm. 
    276.  Remove and  discard the two  Nyloc  nuts retaining 
    277.  Remove  the detent  plate  and  spring  from the 
    278.  Clean 
    all parts, examine for wear or damage, 
    the detent 
    plate. 
    housing. 
    renew  as necessary. 
    35  
    						
    							137 I LT230R TRANSFER GEARBOX 
    299. Before  refitting  the high/low connecting  rod and 
    gear  change  operating  arms remove  the respective 
    clevis  pins and Nylon  bushes.  Clean and examine 
    for wear or damage,  renew as necessary. 
    300.  Grease  and 
    fit the Nylon  bushes  to the high/low 
    selector  and gear  change  opcrating arms. 
    301.  Assemble  both operating  arms to the  connecting 
    rod  with  clcvis  pin, plain  washer  and split  pin. 
    302.  Slacken  the gear  change  operating  arm clamp  bolt 
    and 
    fit the  operating  arm on to the  splined  shaft 
    projecting  from the 
    high/low gear change 
    housing,  carefully  aligning 
    it to the  marks on both 
    camponents. 
    303.  Tighten  the clamp  bolt to the specified  torque. 
    304.  Before  refitting  the differential  lock cross  shaft 
    lever  and pivot  bracket  remove the respective 
    clevis  pins and Nylon  bushes. 
    Also remove  the 
    split  pin retaining  the cranked  lever and 
    disconnect  it. Clean  and examine  for wear 
    or 
    damage,  renew as necessary. 
    305.- Fit the  cranked  lever to the bottom of thc cross 
    shaft  lever and secure  with a new  split  pin (with 
    plain  washer). 
    NOTE: 
    Early  gearboxes  were fitted  with a short 
    connecting  link secured  by a ‘Nyloc’  nut. 
    II 
    306. Grease  and fit the Nylon bushes to the middle 
    pivot of the  cross  shaft  lever. 
    307. 
    Fit the  cross  shaft  lever  to the (loose)  pivot 
    bracket  with the clevis  pin, washer  and split  pin. 
    308.  Fit the  cross  shaft  lever  fork (top)  to 
    thc gear 
    change  cross shaft. 
    309.  Locate  the anti
    -rattle Nylon strip  and fit the clevis 
    pin,  plain  washer  and split  pin. 
    310.  Fit the  cranked  lever, 
    at thc bottom of the 
    differential  lock cross  shaft lever,  to the  lock  lever 
    and  retain  the clevis  pin and  plain  washer  with a 
    new  split  pin. 
    311.  Grease  and 
    fit the Nylon  bushes  to the  operating 
    arm  on the  selector  housing  cross shaft. 
    Adjustment of highllow connecting  rod 
    312. 
    313. 
    314. 
    315. 
    316. 
    317. 
    318. 
    319. 
    36 
    This  operation  is carried  out in situ or on the 
    bench,  after assembly  to the  main  gearbox. 
    Remove  the 
    four bolts from the top  of the  gear 
    changc  housing  and 
    lift off the gear changc  lever 
    grommet  plate and the gcar  change  lever 
    grommet.  Replace the four  bolts 
    tcmporarily to 
    retain  the gate  plate  in position. 
    Check  that 
    the gear lever  does not foul the gate 
    plate  when  high or low  range  is selected. 
    If 
    adjustment  is required  carry out the following 
    procedure.  *Slacken  off the  connecting  rod locknuts. 
    Move  gear change  lever into high  range 
    (rearwards)  and move  the operating  arm 
    on the 
    selector housing cross shaft into high  range 
    (forwards). 
    Tighten 
    locknut(s). 
    Check  that the gear  change  lever does not foul  the 
    gate  plate 
    in this position. 
    Engage  and check  low range  in the  same  way.  320. 
    After  adjustment  return the gear  change  lever to 
    the  high  range  position. 
    321.  Remove  the four  bolts  retaining  the gate  plate  and 
    refit  the grommet  and grommet  plate. 
    322.  Refit  the four  bolts  (with  spring  washers). 
    * On early versions of the transfer  gearbox  a different 
    connecting  rod fork  end was  used 
    with a single 
    locknut. 
    In this  case  the following  method of 
    adjustment  is recommended. 
    (a)  Disconnect 
    the top of the  differential  lock 
    cross  shaft lever  from the gear  change  cross 
    shaft. 
    (b)  Remove  the four  bolts  retaining  the gear 
    change  housing  to the 
    remote gear  change 
    housing 
    on the main  gearbox. 
    (c)  Lift  up the  housing  assembly  (with the 
    connecting  rod attached)  and rotate 
    it as 
    required 
    to vary  the length  of the connecting 
    rod. 
    Transfer  box mounting - Refitting 
    323.  Fit the rubber  mounting  plate to the  right  sidc of 
    the  front  output  housing  by fitting  the 
    four 
    securing  bolts (with  new lock  tabs). 
    Handbrake  linkage - Refitting 
    324. Locate  the handbrake  linkage bracket in position 
    on the right  hand  side of the  transfer  box casing 
    and  secure 
    as follows. 
    325.  Fit the  two  bolts  (with  spring  washers)  and 
    distance  pieces to retain  the front  sidc 
    of the 
    linkage  bracket. 
    ST 
    326. Fit the  two  bolts  (with  spring  washers)  to secure 
    the  rear  end 
    of the linkage  bracket.  The lower 
    bolt  is shorter. 
    327. 
    Insert the  clevis  pin through the brake  operating 
    lever, 
    fit the  handbrake  link, plain  washer  and 
    split  pin. 
    . :/  
    						
    							LT230R TRANSFER GEARBOX (371 
    .- .I:. .:. DATA L ..-!: ;.:: ....... ., ./ ..,, .. ....... .... 
    Input shaft bearing pre-load .................................. 
    Intermediate gear end-float .................................. 
    Centre differential  rolling  resistance - (minus 
    intermediate gear cluster and output  shaft flange) 
    ...... 
    Input gear rolling  resistancc - (minus 
    intermediate  gear cluster) 
    ..................................... 
    Differential  pinions backlash ................................. 
    Output shaft bearing  pre-load ............................... 
    Low range  gear end-float 
    Intermediate 
    gear thrust washer  thickness 
    ................ 
    High range gear end-float ..................................... 
    High range gear/bush running  clearance  diameter ...... 
    0,02 to 0,07 mm (0.001 to 0.003 inch) 
    0,08 to 0,35 mm (0.003 to 0.014 inch) 
    2,?0 to 2,75 mm (1.06 to 1 .@8 in) 
    1,8 to 4,5 Kg (4 to 10 Ib) pull 
    1,4 to 3,6 Kg (3 to 8 Ib) pull 
    0,02 to 0,07 mm (0.001 to 0.003 inch) 
    0,02 to 0,0? mm (0.001 to 0.003 inch) 
    0,05 to 0,15 mm (0.002 to 0.006  inch) 
    0,03 to 0,09 mm (0.0012 to 0.0035 inch) 
    < , 
    37  
    						
    							371 LT 95 FOUR SPEED GEARBOX 
    REMOVE LT 95 FOUR SPEED  GEARBOX  WITH 
    MODELS  INTEGRAL 
    TRANSFER  BOX 
    - ONE TEN V8 
    Service  tools: 
    RO 1001 - Lifting bracket  for gearbox.  A hydraulic  or 
    mechanical  chassis spreader 
    is also required. 
    The  gearbox  should be removed  from underneath the 
    vehicle  using a suitable  lifting hoist. Number 3, chassis 
    cross
    -member  is removable  to allow easy removal of 
    the gearbox. 
    WAKNING:  It is essential, because of the considerable 
    weight  and offset  position 
    of the centre  of gravity  of the 
    gearbox,  that 
    a hydraulic transmission  hoist of adequate 
    strength  and stability 
    is used.  Failure  to observe  this 
    precaution  could result  in the  hoist  tipping  over and 
    causing  serious personal  injury 
    or damage to the 
    gearbox. 
    Suitable  hydraulic  lifting  equipment (A) is made  by 
    Blackhawk 
    International Limited.  A special  adaptor 
    plate  (B) is produced  by Claydrum  Engineering 
    Services for holding the Land Rovcr V8 gearbox.  This 
    adaptor  plate  can be used  with various  transmission 
    hoists  provided  they meet  the  safety  requirements 
    indicated  above. 
    Remove 
    Gear change  levers. 
    Central  section 
    of exhaust system. 
    Disconnect 
    Handbrake  and speedometer  cables. 
    Front  and rear propeller shafts  from the gearbox. 
    Vacuum  pipes and electrical  leads  from differential 
    lock  actuator. 
    Electrical  leads from  reverse light switch. 
    Make  any remaining  disconnections  and  note 
    the 
    following important  points during  removal. 
    38 
    it to fall. Aftcr  removing the fixings,  use a spreader  on 
    When removing 
    the chassis  cross
    -member,  do not  allow 
    the  chassis side  members 
    to free the cross-member. 
    Remove  the cover  plate from the front  lower  half of the 
    bell housing. 
    Remove  the clutch  slave cylinder from the  bell housing. 
    Position  the transmission  hoist under  the gcarbox  and 
    support 
    it. 
    Release  the two rear  gearbox mounting brackets  from 
    the  chassis side 
    mcmbers. 
    Support the engine under  the sump. 
    Pass the safety  chain around  the gearbox  and make 
    fast. 
    Remove 
    the bell  housing bolts  (eight bolts). 
    Withdraw  the gearbox  from 
    thc engine. 
    Fit the lifting  bracket  RO 1001  to facilitate  any 
    I -a 
    t. ds 
    subsequent  removal from the transmission lift. 
    After  refitting  the  gearbox into the vehicle, refill the 
    main  and transfer  gearboxes 
    with the correct grade oil, 
    to the  oil level  plug hole. 
    For  further  information regarding the  hydraulic 
    transmission  hoist and the special  gearbox  adaptor 
    plate,  please  contact  the  equipment manufacturers 
    direct.  Their addresses  are as 
    follows:- 
    Transmission  Hoist - type 67556 (T-3) 
    Blackhawk Automotive Limited 
    Brookfield Industrial  Estate 
    Leacon Road 
    Ashford 
    Kent, England 
    Tclcphonc: Ashford  (0233) 32151 
    Telex:  965621  BLUK G 
    Gearbox  Adaptor Plate - type DS RT 
    Claydrum  Engineering  Services 
    P.0. Box 5 
    Clayland Avenuc 
    Worksop, England 
    Tclcphone Worksop (0909) 4802 1  
    						
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