Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual
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LT230T TRANSFER BOX OVERHAUL MANUAL This transfer box is fitted to the following models: Serial No. Prefixes: 20D, 22D, 32D, 43D, 47D, 56D, 57D, 58D, 59D, and 60D - Defender Serial No. Prefixes: 28D, 34D, 41D, 42D - Discovery Serial No. Prefixes: 14D, 15D, 20D, 26D, 27D, 28D and 30D - Range Rover Classic Publication Part No. LRL 0081ENG - 3rd Edition Land Rover 2000 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior permission from Land Rover.
INTRODUCTION CONTENTS Page INFORMATION INTRODUCTION 1...................................................................................................... REPAIRS AND REPLACEMENTS 2........................................................................... SPECIFICATION 2......................................................................................................
INTRODUCTION INTRODUCTION1 INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevant sub-section is given at the bottom each page. This manual contains procedures for overhaul of the LT230T transfer box. For all other information regarding adjustments and removal of oil seals, consult the Repair Manual for the model concerned. This manual is divided into 3 sections: Description and Operation, Overhaul and Data, Torque & Tools. To assist filing of revised information, each sub-section is numbered from page 1. Individual items are to be overhauled in the sequence in which they appear in this Manual. Items numbered in the illustrations are referred to in the text. Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool. Where usage is not obvious the tool is shown in use. Operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details. WARNINGS, CAUTIONS and Notes have the following meanings: WARNING: Procedures which must be followed precisely to avoid the possibility of injury. CAUTION: Calls attention to procedures which must be followed to avoid damage to components. NOTE: Gives helpful information.References Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned Dimensions The dimensions quoted are to design engineering specification with Service limits where applicable.
INTRODUCTION 2 INTRODUCTION REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Land Rover recommended parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories. Safety features and corrosion prevention treatments embodied in the car may be impaired if other than Land Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer’s specification. Torque wrench setting figures given in this Manual must be used. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. The terms of the vehicle Warranty may be invalidated by the fitting of other than Land Rover recommended parts. All Land Rover recommended parts have the full backing of the vehicle Warranty. Land Rover Dealers are obliged to supply only Land Rover recommended parts.SPECIFICATION Land Rover are constantly seeking to improve the specification, design and production of their vehicles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular component or vehicle. This Manual does not constitute an offer for sale of any particular component or vehicle. Land Rover Dealers are not agents of the Company and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
TRANSFER BOX CONTENTS Page DESCRIPTION AND OPERATION FRONT OUTPUT HOUSING COMPONENTS 3......................................................... DIFFERENTIAL COMPONENTS 5.............................................................................. MAIN CASING COMPONENTS 7............................................................................... REAR OUTPUT HOUSING AND TRANSMISSION BRAKE COMPONENTS 9.......... TRANSFER BOX CROSS SECTION 11..................................................................... DESCRIPTION 12....................................................................................................... OPERATION 13........................................................................................................... Power flow - transfer box in LOW ratio 14................................................................... Power flow - transfer box in HIGH ratio 15................................................................... OVERHAUL TRANSFER BOX DISMANTLING 1............................................................................ COMPONENT DISMANTLING 6................................................................................. High/low cross shaft housing 6.................................................................................... Front output housing 7................................................................................................. Rear output housing 10................................................................................................ Main casing 12............................................................................................................. Mainshaft input gear bearing housing 13..................................................................... Intermediate gears 13.................................................................................................. Mainshaft input gear assembly 14............................................................................... Differential lock selector 14.......................................................................................... Differential 15............................................................................................................... INSPECTING COMPONENTS 18............................................................................... Intermediate gears and shaft 18.................................................................................. Mainshaft input gear 19............................................................................................... High/low cross shaft and housing 19........................................................................... Front output housing and differential lock selector 20.................................................. Rear output housing 22................................................................................................ Main casing 22............................................................................................................. Mainshaft input gear bearing housing 23..................................................................... High/low selector fork and shaft 23.............................................................................. Differential 24............................................................................................................... COMPONENT ASSEMBLING 25................................................................................ Differential 25............................................................................................................... Main casing 30............................................................................................................. Mainshaft input gear bearing housing 31..................................................................... Mainshaft input gear assembly 31............................................................................... Intermediate gears 32.................................................................................................. Rear output housing 32................................................................................................ Front output housing 34............................................................................................... High/low cross shaft housing 36.................................................................................. Differential lock selector 36.......................................................................................... TRANSFER BOX ASSEMBLING 37............................................................................ Mainshaft input gear bearing pre-load 37.................................................................... Rear output housing 38................................................................................................ Differential bearing pre-load 39.................................................................................... Front output housing 41............................................................................................... Intermediate gears 43.................................................................................................. Bottom cover 46........................................................................................................... High/low selector shaft detent 47................................................................................. Interlock solenoid - if fitted 47......................................................................................
TRANSFER BOX CONTENTS Page Neutral warning lamp switch - if fitted 48..................................................................... Differential lock warning lamp switch - adjust 48......................................................... Transmission brake 49................................................................................................. DATA, TORQUE & TOOLS DATA1 ........................................................................................................................ TORQUE FIGURES 2.................................................................................................. SERVICE TOOLS 3.....................................................................................................
TRANSFER BOX DESCRIPTION AND OPERATION1 This page is intentionally left blank