Land Rover Lt230t Transfer Box Overhaul 3rd Edition Rover Manual

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36
OVERHAUL High/low cross shaft housing
1.Lubricate cross shaft and new’O’ring with
recommended oil.
2.Insert cross shaft into housing, position
high/low selector finger on shaft.
3.Fit’O’ring to shaft, locate end of shaft in
hollow plug.
4.Slide’O’ring on to end of shaft.
5.Align hole in high/low selector finger with
recess in cross shaft.
6.Apply Loctite 290 to threads of setscrew, fit
and tighten screw.
7.Apply Hylomar PL32 sealant to threads of low
detect switch - if fitted. Fit switch, do not tighten
locknut until switch has been adjusted.
NOTE: Switch must be adjusted after
transfer box is installed in vehicle.Differential lock selector
1.Lubricate new’O’rings with recommended oil,
fit to selector finger shaft and housing.
2.Insert selector finger shaft into housing.
3.Fit selector lever ensuring that relative
positions of lever and finger are as shown.
4.Fit washer and new self-locking nut, tighten nut
to 15 Nm (11 lbf.ft). 
						

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TRANSFER BOX ASSEMBLING
1.Lubricate all components with recommended
oil.
CAUTION: Where use of gaskets is
specified, gaskets must be fitted; do not
use sealant.
Mainshaft input gear bearing pre-load
1.Position mainshaft input gear assembly in main
casing.
2.Up to serial no. 288709E:Fit a new mainshaft
input gear bearing housing gasket, dry on main
casing.
3.All transfer boxes:Fit mainshaft input gear
bearing housing ensuring reference marks are
aligned.
4.Fit 2 M10 x 25 mm bolts and tighten to 25 Nm
(18 lbf.ft).
5.Position suitable DTI with stylus of gauge
contacting end of mainshaft, push mainshaft
rearwards and zero gauge.
6.Push mainshaft forwards and note gauge
reading.7.Calculate thickness of shim required using the
formula A + B + C = D where:
A = Thickness of installed shim - 3.15 mm
(0.12 in)
B = Recorded end-float
C = Required pre-load - 0.05 mm (0.002 in)
D = Thickness of shim required
8.If an alternative shim is required to establish
correct end-float, proceed as follows:
NOTE: Do not remove mainshaft input
gear bearing housing if bearing pre-load is
correct.
9.Remove 2 bolts, remove mainshaft input gear
bearing housing.
NOTE: Up to serial no. 288709E, retain
gasket on main casing.
10.Using a soft metal drift, carefully drive input
gear bearing track out of bearing housing,
remove shim.
CAUTION: If bearing track is damaged
during this operation, a new track must be
fitted.
11.Select required shim from the range available.
NOTE: Shims are available from 3.15 to
4.00 mm (0.12 to 0.16 in) thickness rising
in increments of 0.05 mm (0.002 in).
12.Fit selected shim and using a suitable mandrel,
fit input gear bearing track.
13.Fit mainshaft input gear bearing housing and
temporarily secure using 2 M10 x 25 mm bolts
tightened to 25 Nm (18 lbf.ft). 
						

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38
OVERHAUL Rear output housing
1.Up to serial no. 288709E:Position a new
gasket, dry on main casing.
2.From serial no. 288709E:Apply Hylosil RTV
102 sealant to mating flange of rear output
housing.
3.Fit rear output housing to main casing.
NOTE: Dowel located.
4.Apply Loctite 290 to threads of bolts and
shoulder bolt.
5.Fit washers to 2 bolts.
6.Fit bolts and tighten by diagonal selection to 45
Nm (33 lbf.ft).
7.Fit output flange, new felt and steel washers to
output shaft.
8.Fit a new self-locking nut.
9.Position propeller shaft flange holding tool
LRT-51-003to output flange.
10.Restrain flange, tighten nut to 162 Nm (120
lbf.ft).
11.Lubricate a new’O’ring with recommended oil
and fit to vehicle speed sensor - if fitted.
12.Fit vehicle speed sensor - if fitted.
13.Fit and tighten Allen screw. 
						

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OVERHAUL39
Differential bearing pre-load
1.Position high/low selector shaft and fork to
differential ensuring that fingers of selector fork
are located in high/low selector sleeve.
2.Position high/low selector shaft and differential
in main casing ensuring that splines of rear
output shaft are engaged in differential.
3.Position new differential front bearing outer
track on bearing ensuring that track is seated
squarely.
4.Position setting block, toolLRT-41-014/3on
main casing.
5.Screw pillarLRT-41-014/4into tapped hole in
main casing.
6.Assemble DTILRT-99-006to pillar.
7.Position stylus of DTI to setting block, zero
gauge.
8.Position stylus of gauge on front bearing outer
track, record reading obtained.
9.Position stylus of gauge on opposite side of
bearing track, record reading obtained.
CAUTION: Ensure that bearing outer track
is not disturbed when carrying out above
operations.
10.Establish average of the 2 readings, record
figure obtained. 
						

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OVERHAUL
11.Position front output housing as shown.
12.Up to serial no. 288709E:Position a new
gasket, dry, on front output housing.
13.Position depth block, toolLRT-41-014/2and
cross-bar, toolLRT-41-014/1on front output
housing.
14.Position DTILRT-99-006on cross-bar
LRT-41-014/1.
15.Zero DTI on depth blockLRT-41-014/2.
16.Position DTI to cross-barLRT-41-014/1,record
reading obtained.
17.Remove tools.
18.Up to serial no. 288709E:Remove and retain
gasket.
19.Using the formula:
3.05 mm (0.120 in) + B - A = D where:
B = Height difference recorded between depth
block and cross bar
A = Average of readings to differential front
bearing outer track
D = Thickness of shim required to give
differential bearing pre-load of 0.05 mm (0.002
in)
20.From resultant figure obtained, select
appropriate thickness shim from the range
available.
NOTE: Shims are available from 2.00 to
3.25 mm (0.08 to 0.13 in) thickness rising
in increments of 0.05 mm (0.002 in).21.Retain selected shim and differential front
bearing outer track with front output housing.
22.Up to serial no. 288709E:Retain gasket with
front output housing.
23.Carry out assembly of front output housing-
See Component assembling. 
						

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OVERHAUL41
Front output housing
1.Up to serial no. 288709E:Fit gasket used
when determining differential bearing pre-load,
dry, to main casing.
2.From serial no. 288709E:Apply Hylomar RTV
102 sealant to mating flange of front output
housing.
All transfer boxes
3.Fit front output housing ensuring that splines of
output shaft are engaged in differential and that
internal splines of dog clutch are engaged with
teeth of output shaft.
4.Apply Loctite 290 to threads of bolts, fit bolts
noting that longest bolt is inserted through
high/low selector finger housing.
5.Tighten bolts by diagonal selection to 25 Nm
(18 lbf.ft).
6.Fit output flange, new felt and steel washers to
output shaft.
7.Fit a new self-locking nut.
8.Position propeller shaft flange holding tool
LRT-51-003to output flange.
9.Restrain flange, tighten nut to 162 Nm (120
lbf.ft).
10.Compress differential lock selector spring and
fit to selector fork.
11.Locate fingers of selector fork in groove in dog
clutch.
12.Fit differential lock selector shaft ensuring end
of shaft is located in recess in rear of housing.
13.Rotate selector shaft until the two flats for the
retaining clips are at right angles to the cover
plate mating face. 
						

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OVERHAUL
14.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
15.Fit differential lock detent ball and spring.
16.Apply Loctite 290 to threads of detent plug.
17.Fit and tighten detent plug then unscrew 2 full
turns.
18.Ensure’O’ring is correctly located on
differential lock selector housing.
19.Fit differential lock selector assembly ensuring
that selector finger is located in recess in
differential lock selector shaft.
20.Apply Loctite 290 to threads of bolts.
21.Fit bolts and tighten to 25 Nm (18 lbf.ft).
22.Operate differential lock selector lever and
check that differential lock detent ball can be
felt to positively engage and disengage with
grooves in selector shaft; screw detent plug in
or out until setting is correct.
23.Early boxes:Fit locknut to differential lock
warning lamp switch.
24.Later boxes:Fit spacer to differential lock
warning lamp switch ensuring that counterbore
on spacer is towards top of switch.
25.Apply Hylomar PL32 sealant to threads of
differential lock warning lamp switch, fit and
tighten switch.
CAUTION: Do not allow sealant to contact
switch plunger and where switches are
fitted with a locknut, do not tighten
locknut or fit differential lock side cover until
switch has been adjusted.
Switches fitted with a spacer
26.Apply sealant, Part No. STC 3254 to mating
face of differential lock side cover, fit cover.
27.Apply Loctite 290 to threads of side cover
bolts, fit bolts and tighten to 25 Nm (18 lbf.ft). 
						

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OVERHAUL43
All boxes
28.Up to serial no. 288709E:Apply grease to new
high/low selector housing gasket, position
gasket on front output housing.
29.From serial no. 288709E:Apply sealant, Part
No. STC 3254 to mating flange of high/low
selector housing.
30.Fit housing ensuring that high/low selector
finger is located in recess in high/low selector
shaft.
31.Fit 6 bolts and tighten to 25 Nm (18 lbf.ft).Intermediate gears
CAUTION: The spacer fitted must be of the
selective length, non-collapsible type, DO
NOT fit a collapsible spacer.
1.Using a micrometer, measure the width of each
bearing inner track.
2.Record each reading as measurement’A’and
’B,’both measurements should fall within range
of 21.95 to 22.00 mm (0.864 to 0.866 in). 
						

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OVERHAUL
3.Fit bearing inner track’A’on to tool post
ofLRT-41-017and position intermediate gears
on to bearing’A.’
4.Fit bearing inner track’B’to intermediate
gears, apply finger pressure to bearing inner
tracks and rotate gears 5 to 10 turns to settle in
bearing rollers.
5.Attach a DTI to base ofLRT-41-017, zero
gauge on top of tool post and take 2
measurements at 180°of the step height
between the top of the tool post and the inner
track of the bearing, take an average of the 2
readings and record this as measurement’C’.
Measurement’C’should be in the range of
0.15 to 0.64mm (0.006 to 0.025in).
6.Using the formula 103.452mm (4.0729in) -’A’-
’B’-’C’calculate the length of bearing spacer
required. From the result of the calculation
round DOWN to the nearest length of spacer
available to give a correct bearing pre-load of
0.05mm (0.002in).
NOTE: There are 40 selective spacers
available ranging in length from 58.325mm
(2.296in) to 59.300mm (2.335in) in
increments of 0.025mm (0.001in).
7.Remove intermediate gear assembly from
LRT-41-017.
8.Lubricate and fit bearings and selected spacer
to intermediate gears.
9.Wrap a suitable length of wire around
intermediate gears and using assistance, lower
gears into main casing ensuring that they are
meshing with input and differential gears.
CAUTION: Do not remove wire at this
stage.
10.Lubricate new’O’rings with recommended oil
and fit to intermediate shaft and main casing. 
						

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OVERHAUL45
11.Raise intermediate gears until dummy shaft
LRT-41-004can be inserted from front output
housing side of main casing.
12.Fit intermediate shaft, drift shaft into position
whilst at the same time expelling dummy shaft
LRT-41-004 .
CAUTION: Ensure’O’ring is not displaced
from main casing.
13.Remove wire from around intermediate gears.
14.Rotate intermediate shaft until retaining plate
can be located on flat on shaft.
15.Apply Loctite 290 to threads of retaining plate
bolt.
16.Fit bolt and tighten to 25 Nm (18 lbf.ft).
17.Fit a new intermediate shaft nut and tighten to
88 Nm (65 lbf.ft).
CAUTION: Do not stake nut at this stage.
18.Select neutral.
19.Screw a suitable bolt into tapped hole in end of
toolLRT-41-005.
20.Insert toolLRT-41-005in end of mainshaft.
21.Using a suitable torque meter on tool
LRT-41-005, check torque to turn of transfer
box gear train :
Torque to turn = 2.2 Nm (19 lbf.in)
22.If torque to turn figure is incorrect, intermediate
gear bearing pre-load setting procedure must
be repeated. When torque to turn figure is
correct, remove toolLRT-41-005and stake
flange of intermediate shaft nut into recess in
intermediate shaft.
NOTE: Discovery cover plate illustrated.
23.Up to serial no. 288709E:Fit and tighten 2
countersunk screws to secure mainshaft input
gear bearing housing.
24.Remove bolts used to temporarily secure
mainshaft input gear bearing housing.