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