Land Rover 90 110 Workshop Rover Manual

							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 
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							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 
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							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  
						

							LT230T TRANSFER BOX 
-_ .. . . _. . (.,. .. , , .: .... .. .... :  ... .. 11. Remove the eight  retaining bolts and lift off the 
12. Release the retaining  ring and remove  front  upper 
13. Rcmove the pinion  gears and  dished washers along 
14. Remove  the rear  lower  bevel gear and thrust 
front 
part 
of the differential unit. 
bevcl gear  and thrust  washer. 
with  the cross  shafts. 
asher from the rear  part of the differential unit. 
114 
ST 1 
15.  Remove thc rear differential unit from thc vicc and 
clean  all components; 
examine Tor wcar or clamage 
and  renew if necessary. 
16. Clean  all components; examine  for wear  or damage 
and  renew 
if necessary. 
17. Using  soft  jaws  secure  the rear differential unit in 
the vice  by gripping  the hub splincs. 
IS. Ensure that all differential  components  arc  dry to 
assist 
in checking  end-float. 
19. Using a micrometer, measure one  of the bevel gear 
thrust  washers  and note  the thickness. 
20.  Fit the  thrust  washer and bevel  gear 
to the  rear 
lower differential  unit. 
21.  Assemble  both  pinion 
asscmblies and dished 
washers  on 
to their respective shafts  and fit to the 
rear  differential  unit. 
22. Measure the front upper  bevel gear thrust  washer 
and note  the thickness. 
23. Fit the thrust  washer  and bevel  gear to the front 
unit. 
24.  Refit  the retaining  ring and front  differential  unit, 
aligning  the two  engraved  arrows  marked on  both 
halves  of the unit. 
25. 
Fit four bolts  equi-spaced  and torque  to the  correct 
figure. 
25- 
26. Mcasure the  front  bevel  gear end-float  with fcclcr 
gaugcs through  the slots  provided in the front 
differential 
unit. The end-float  must be 0,025 to 
0,075 mm (0.001 to 0.003 in) maximum.  When 
measuring  use  two sets 
of feelcr gauges,  one  on 
each  side of the  front  differential  unit.  This 
will 
give a true reading  of the  end-float. 
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							137 I LT230T TRANSFER BOX 
27. Invert the differential  unit  and repeat operation 26 
for the  rear  bevel  gear end-float. 
28. Invert  the  differential  unit and secure  in vice  and 
remove  the  four  bolts  and 
lift off the  front 
differential unit. 
29. Remove  the rctaining  ring, bevel  gear  and  the 
washer  and both pinion assemblies. 
30. Select the  correct  thrust washers  required  for  final 
assembly. 
Reassembling 
31. Fit the  selected  thrust washer and bevel gear into 
the  rear  lower  differential  unit. 
32. Assemble  both pinion  assemblies  and dished 
washers 
on to their  respective shafts  and fit the  rear 
differential  unit.  Secure 
the assemblies with the 
retaining  ring. 
33. Lubricate  all the  components. 
34. Fit the  selected  thrust washer  and  bevel gear into 
the  front  upper  differential  unit. 
S7 1 602 
ST 
35. Align both  units as previously  described and secure 
with  the eight 
bolts to the  specified  torque. 
36. Finally check that the differential  gears rotate 
freely.  Locate  the  front  differential  bearing onto 
the front,  upper  differential  shaft and press  into 
position 
using larger  end of tool 1861424 as shown. 
37. Invert the differential  unit and secure in the vice. 
NOTE: During  the following  sequences all parts 
should be lubricated  as they  are fitted. 
98 
38. Fit the  low  range  gear, with its dog  teeth  upper- 
most  to the  differential assembly. 
39. Prcss the highllow hub on to the differential 
spli 
nes. 
40. Slide  the high/low selector  sleeve on to the high/ 
low hub ensuring  that the alignment  marks  are 
opposite each  other. 
41. Fit the bush  into the high  range  gear so that the 
flange  is fitted 
on the  opposite  side of the gear to 
thc dog teeth.  Slide the bushed  gear on to the 
differential  assembly with the dog teeth down. 
41 
39 
ST1599M