Land Rover Defender Workshop 1993 Rover Manual

							LT230T TRANSFER  GEARBOX 
42. Locate  the rear  differential  bearing on to the  46. Clean  and check  high/low  selector fork 
hub  and  press 
it into position  using the  assembly for wear  and renew if necessary. 
smaller  end 
of tool 18G1424,  see instruction  47. To renew the selector  fork remove  the set 
36. screw  and slide  the fork  from  the shaft. 
43.  Fit 
the  stake  nut and  tighten 
to the specified  48. Fit 
the  new  selector  fork with  its boss  towards 
torque  using 
tool 18G1423.  the 
three  detent  grooves.  Align the tapped 
44. Check  the end  float  of the  high  and low range  hole in the  fork  boss  with the indent  in the 
gears 
0,05 to 0,15 mm  (0.002 to 0.005 in).  shaft 
nearest to the detent  grooves. 
49.  Apply  Loctite 
290 to the  set screw  threads 
and 
fit the  set screw  and tighten to the 
specified  torque. 
NOTE: If the clearances  vary from  those 
specified,  the assembly  must 
be rebuilt 
using  the relevant  new 
parts. 
45. Peen  the stake  nut collar  by carefully  forming 
the  collar 
of the  nut  into the slot as illustrated. 
CAUTION: A round  nose tool must  be used 
for  this  operation  to avoid  splitting  the 
collar  of the  nut.  Centre 
differential  rear bearing  track 
50. Fit the  differential  rear bearing  track 1,00 mm 
(0.039 in) below  the outer  face of casing  using 
a 
suitable tool as shown. 
20 REISSUED:  FEB 1993  
						

							LT230T TRANSFER GEARBOX 
Rear  output housing - refit 
1. Grease output housing  gasket and position on 
to the  rear  face  of the  transfer  box casing. 
2. Fit output  housing  and ensure  clearance  of 
100 mm (0.039 in) between  housing face and 
gasket. 
3. Fit the  six output  housing  bolts with Loctite 
290 on the  threads,  with washers  and tighten, 
evenly  to the  correct  torque,  which 
will pull the 
rear  bearing  into position. 
3. Fit selector  shaft ball and  spring  through  the 
side 
of the  transfer  box casing. 
4. Apply  Loctite 290 to detent  plug; fit and- 
locate, by screwing  gently fully home  and then 
unscrewing  two turns. 
Centre differential unit  refit 
1. Fit the  selector  fork/shaft  assembly to the 
high/low  selector sleeve 
on the differential 
assembly,  with detent  groove 
to the rear of 
the differential  assembly. 
2. Locate the differential  assembly complete with 
selector  fork into the transfer  box casing. 
It 
may  be necessary  to rotate the output  shaft to 
ease  fitment,  and engage  selector  shaft into 
its  hole.  
						

							LT230T TRANSFER GEARBOX 
Front  output housing dismantle  and overhaul 6. Withdraw  the selector  shaft from the rear  of 
the  output  housing. 
1. Unscrew  seven retaining  bolts and washers 7. Remove  the selector  fork and  spring  through 
the  side  cover  aperture. 
8. Remove  lock - up sleeve  from the rear of the 
and 
remove  the differential  lock selector  side 
2.  Unscrew  three 
retaining bolts and washers  output housing. 
and 
lift the  differential  lock finger  housing  and 
actuator  assembly 
from the front  output 
3. 
Slacken the  locknut  and unscrew  the 
4. 
Remove  slector  shaft detent  plug, spring  and 
9. Using  flange  wrench 18G1205 and socket 
wrench,  remove the flange  nut, 
steel and felt 
washers. 
NOTE: Ensure  that flange  bolts  are fully 
engaged in the  wrench. 5. Compress  the selector  fork spring  and remove 
the  two  spring  retaining  caps. 
cover and gasket. 
housing.  differential  lock  warning  light switch. 
ball using a suitable magnet.  
						

							LT230T TRANSFER GEARBOX 
10. Remove  the output  flange  with oil seal  shield. 16. Drift  out centre  differential  front taper  roller 
bearing  track and shim. 
NOTE: These  parts need not be separated 
unless  the flange  bolts are to be  renewed. 
11.  Drift  output  shaft rearwards  from housing 
using  a soft  headed  mallet. 
12. Slide off the collar  from the output  shaft. 
13. Remove  and discard  oil seal  from  output 
housing  using service  tool 18G1271  to avoid 
damaging  the housing. 
14. Remove  circlip with circlip  pliers 18G257. 
17. Drift out selector  shaft cup plug  from  housing. 
18. Clean  all components  ensuring all traces of 
Loctite  are removed  from faces  and threads. 
19. Examine  components  for wear  or damage  and 
renew 
if necessary. 
NOTE:  Renew oil seal  and felt seal  and 
flange  nut. 
15. Invert  housing  and drift  out bearing  from 
inside  the case  as shown. 
Re-assembling  front output  housing 
20. Press  the bearing  into the housing:  do not  use 
excessive  force. 
To facilitate fitting the 
bearing,  heat the front  output  housing 
uniformally 
to a  temperature  that must  not 
exceed  100°C (212°F). 
21. Using  circlip  pliers,  fit the  bearing  retaining 
clips.  
						

							LT230T TRANSFER GEARBOX 
22. Pre - grease and fit a new  oil seal  (lip side 
inwards)  using replacer 
tool 18G1422, until 
the seal  just makes  contact  with the circlip. 
29. Grease  and 
fit new gasket  and locate  the front 
output  housing  on the  transfer  box casing. 
30.  Secure  housing  with the eight  retaining  bolts 
and  washers,  the upper  middle  bolt being 
longer  than the rest.  Do not  tighten  the bolts 
at  this  stage. 
31.  Engage  high or 
low gear. 
32.  Check  the roiling  resistance  of the  differential 
using 
a spring  balance  and a length of string 
wound  around  the exposed  splines of 
the 
high/low  hub. 
23. 
Carefully  charge the lips 
of the seal  with clean 
grease. 
24.  Slide  collar  on to the  output  shaft, with its 
chamfered  edge away  from the dog  teeth. 
25. Fit the output  shaft through  the bearing  and 
drift  home. 
Adjusting  front differential  bearing pre - load 
26.  Measure  original differential  front bearing track 
shim. 
27.  Refit original  shim into input  housing. 
28.  Drift differential  front bearing  track into the 
housing.  
						

							LT230T TRANSFER GEARBOX 
33. With the  correct  shim fitted  the load to turn NOTE:  Ensure  that the flange  bolts are 
should  be 1,36  kg to 4,53  kg (3 Ib to 10 Ib). 
NOTE: Alternatively,  fit the nut to the 41. Repeat  the above  operation  for the  rear  output 
output  flange  and  use a suitable  torque 
wrench  to turn  the differential.  The 
readings  should 
be 0.56 to 1.69 Nm (5 to 
15 
in Ib).  New  bearings  will register  at  the 
top end of the  torque  range  and  used 
bearings  will register  at the low  end. 
NOTE: Shims  are available  in 0.001  in 
increments.  fully 
engaged  in the  wrench. 
flange. 
34. 
If the  reading  is in  excess  of the  above 
measurements,  remove  the  front  output 
housing  assembly  from  the transfer  box 
casing. 
35. Using  a suitable  extractor,  withdraw  the centre 
differential  bearing  track  and  change the shim 
for  one  of a suitable  thickness. 
(A thinner 
shim 
will reduce  the rolling  resistance). 
36.  Fit the  new  shim  and  drift the differential 
bearing  track back into its housing  until fully 
home. 
37.  Having obtained  the load 
to turn,  prop - up the 
transfer  box casing  on the  bench  with  the 
front  face  uppermost.  42. 
Compress  the  selector  shaft  spring  and 
fit to 
housing  retaining  bolts  and  fit  the eight  bolts 
43. Locate selector  fork  through  front output 
and  washers  into the front  output  housing  and  housing  side cover  aperture,  ensuring that the 
secure  to transfer  box casing.  fork 
engages  in the  groove  of the 
lock - up 
39. 
Fit front  output  flange,  felt  washers, steel  sleeve. 
washers  and  flange nut. 
44. Fit selector  shaft  through  the  aperture  in the 
40.  Using  flange  wrench 18G1205  and torque  front 
of the output  housing  and pass it through 
wrench,  pull the output  shaft  up 
to the correct  the  selector  fork  lugs and spring  into  the  rear 
position.  Check that the oil seal  shield  does  part of the  housing. 
not foul  the housing.  45. 
Rotate the 
selector  shaft  until the 
two flats for 
the  spring retaining  caps are at right  angles  to 
the  side  cover  plate  face. 
38. 
Apply  Loctite  290 
to the  threads  of the  the select  fork.  
						

							LT230T TRANSFER GEARBOX 
46. Compress  the spring  between  the fork  lugs Differential  lock finger  housing  - dismantle and 
and slide  the retaining  caps on to the shaft overhaul 
ensuring the spring  is captured  with the 
cupped  side of the  caps. 
1. Unscrew  and discard  the nyloc  nut and 
47. Apply  a suitable  sealant to a new  seal cup  remove the operating  lever and washer. 
and  drive  the cup  into position. 
2. Remove  the pivot  shaft  from lock finger 
housing. 
3. Remove  the 0 rings from the pivot  shaft  and 
housing  and discard. 
4. Clean  all components;  examine for wear  or 
damage  and renew 
if necessary. 
Re-assembling 
5. Fit new  O rings  on to pivot shaft and lock 
finger  housing  and lubricate  with oil. 
6.  Locate  the pivot  shaft  in the  housing. 
7. Fit the  differential  lock lever  over the pivot 
shaft 
so that  the lever  will face  forward to the 
bend  upwards. 
This  lever  is  then 
in the correct  operating 
position. 
8.  Retain  the lever  with a plain  washer  and new 
nyloc  nut. 
48. 
Fit selector  shaft detent  ball and  spring  in the 
tapped 
hole on  top  of the  output  housing. 
49. Apply  Loctite 290 to detent  plug threads. 
Screw  detent plug gently  home and then 
unscrew 
two turns. 
Continued  
						

							LT230T TRANSFER GEARBOX 
9. Fit the  differential lock finger  housing  into its 
seating on the  front  output  housing,  ensuring 
that  the selector  finger is located  in the  flat 
of 
the selector  shaft. 
10. Apply Loctite 290 to the bolt  threads  and 
retain  the 
lock finger  housing  with the three 
bolts  and washers 
to the specified  torque. 
11. Grease and fit the high/low  selector housing 
gasket  on the  front  output  housing. 
12. Fit high/low  cross - shaft housing,  ensuring 
that  the selector  finger locates  in the 
slot of 
the  selector  shaft, and secure  with 
six bolts 
and  washers  to the  specified  torque. 
High/low cross - shaft housing  overhaul 
1. Release  the locknut  and remove  the neutral 
warning  switch. 
2.  Remove  the selector  finger set screw  and 
withdraw  the cross
-shaft  from the cross-shaft 
housing  and remove  the selector  finger. 
3.  Remove  the 0 ring  from  the cross
-shaft. 
4.  Drive  out selector  housing  cup plug  if 
necessary. 
5.  Clean  all the  components  and check  for 
damage  or wear,  replace  if necessary. 
6.  Apply  sealant  to a new  cup plug  and fit so 
that  the cup  is just  below  the chamfer  for the 
cross 
- shaft  bore. 
7.  Fit new  ‘O’ ring  to cross 
- shaft. 
8.  Lubricate  the shaft  and insert  into the cross 
- 
shaft  housing. 
9.  Fit selector  finger ensuring  that it aligns  with 
the  recess  in the  cross 
- shaft. 
10.  Apply  Loctite  290 to the  grub  screw  and 
secure  the selector  finger to the  cross 
- shaft 
and  fully  tighten  to the  specified  torque. 
Input gear overhaul  - dismantle  and overhaul 
1. Clean  the input  gear assembly  and examine 
for  wear 
or damage.  Remove the bearings 
only 
if they  are to be renewed.  
						

							LT230T TRANSFER GEARBOX 
2. Secure hand press  MS47  in the  vice  and  7. Prop  up the  transfer  box casing  on the  bench 
using  collars  18G47 
- 7 and  button  18G47 - 
BB/3, remove  rear taper  roller bearing  from 
3. Invert input gear assembly  in hand  press  and 
remove  front taper  roller bearing. 
4. Clean  input gear.  with 
the rear  face  uppermost. 
8.  Drift  in the  front  taper  bearing  track. 
input  gear assembly. 
9. Reposition  transfer box casing so the front 
face  is uppermost  and fit 
oil seal  (lip side 
inwards)  using replacer  tool 18G1422. Re-assembling  input gear assembly 
5. Position  rear taper  roller bearing  on input  gear 
and  using  hand press  MS47  and collars 
18G47 
- 7 press  the shaft  onto bearing. 
6. Invert  input gear and fit the front  taper  roller 
bearing  using the press  and collars. 
10. Lubricate  both bearings  with clean 
oil. 
11.  Fit the  input  gear assembly  into the transfer 
box  casing  with the dog  teeth  uppermost.  
						

							Checking input gear bearing  pre - load 19. Tie  a length  of string to the  split  pin and fit it 
to the  service  tool as shown. 
12.  Secure  bearing  support  plate in the  vice.  Drift  20. Attach  a spring  balance 
to the string  and 
out  input  gear bearing  track, and remove  carefully tension the spring  until a load 
to turn 
shim. 
the input  gear is obtained. A pull of 2,26  kg to 
9 kg (5 Ib to 20 Ib) is required. 
NOTE: Alternatively  using a suitable  torque 
wrench  applied to the  nut on the  service 
tool,  torque  to turn  the input  gear should 
be 0.56 to 2.25 Nm (5 to 20 in Ib). 
21. If the  reading  obtained  is outside  the above 
limits,  the original  shim must  be changed. 
22.  Remove  the spring  balance,  string and service 
tool. 
23. Remove  the six bolts  and the bearing  support 
plate. 
24. Drift  out the  input  gear bearing  track from the 
support  plate and discard  original 
shim. 
25. Select the correct  size shim  to obtain a load 
to turn of 2,26  kg to 9 kg (5 Ib to 20 Ib) or 
torque  to turn 0.56 to 2.25 Nm (5 to 20  in lb). 
26.  Fit shim  to support  plate, locate  bearing  track 
and  press  home. 
27.  Fit bearing  support plate and secure 
to 
13. Clean  bearing  support  plate and shim.  transfer box casing with the six bolts (do not 
Measure  original shim and note  its thickness.  tighten). 
14. Fit the original  shim to the support  plate.  28. Repeat  the rolling  resistance  check as 
15. Locate the bearing  track in the  support  plate  previously described,  and note  the value 
and  press  fully home. 
16. Apply  grease  to the  gasket  and fit on to the 
transfer  box casing. 
17. 
box  casing  and secure with the six bolts,  but 
do  not  tighten, 
18. Fit the  service  tool LST105 to input  gear and 
engage  the spline. 
2. Remove  circlips. 
obtained. 
Fit  the  bearing  support  plate on to the  transfer 
Intermediate  gear assembly  overhaul 
1. Drift out intermediate  gear bearing  tracks.