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Manual Land Rover lt230t

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  • Land Rover lt230t - page 1

    Overhaul Manual L T230T V erdeelbak revisieboek L T230T Boîte de transfert Manuel de révision L T230T V erteilergetriebe Überholungsanleitung L T230T Riduttore Manuale di revisione L T230T Caja de transferencia Manual de revisión L T230T Caixa de velocidades manual Manual de revisão L T230T TRANSFER GEARBOX ...

  • Land Rover lt230t - page 2

    Dealer Stamp Technical Information Review While every attempt is made to ensure that the technical information we supply is as accurate and up to date as possible, from time to time, errors do occur. There may also be instances where the style or content of our publications do not meet your exact needs. We would value your assistance in helping us ...

  • Land Rover lt230t - page 3

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  • Land Rover lt230t - page 4

    LT230T TRANSFER BOX OVERHAUL MANUAL This transfer box is fitted to the following models: Serial No. Prefixes 20D, 22D and 32D - Defender Serial No. Prefixes 28D and 34D - Discovery Serial No. Prefixes 14D, 15D, 20D, 26D, 27D, 28D and 30D - Range Rover Classic Publication Part No. LRL 0081ENG - 2nd Edition Published by Rover Technical Communication ...

  • Land Rover lt230t - page 5

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  • Land Rover lt230t - page 6

    INTRODUCTION CONTENTS Page INFORMATION INTRODUCTION 1 ...................................................................................................... REPAIRS AND REPLACEMENTS 2 ........................................................................... SPECIFICATION 2 .......................................................................... ...

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  • Land Rover lt230t - page 8

    INTRODUCTION INTRODUCTION 1 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, co ...

  • Land Rover lt230t - page 9

    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 ...

  • Land Rover lt230t - page 10

    TRANSFER BOX CONTENTS Page DESCRIPTION AND OPERATION FRONT OUTPUT HOUSING COMPONENTS 3 ......................................................... DIFFERENTIAL COMPONENTS 5 .............................................................................. MAIN CASING COMPONENTS 7 ........................................................................... ...

  • Land Rover lt230t - page 11

    TRANSFER BOX CONTENTS Page Neutral warning lamp switch - if fitted - not Range Rover Classic 51 ........................... Differential lock warning lamp switch - adjust 51 ......................................................... Transmission brake 52 ................................................................................................ ...

  • Land Rover lt230t - page 12

    TRANSFER BOX CONTENTS Page DATA, TORQUE & TOOLS DATA 1 ........................................................................................................................ TORQUE FIGURES 2 .................................................................................................. SERVICE TOOLS 3 ...................................... ...

  • Land Rover lt230t - page 13

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  • Land Rover lt230t - page 14

    TRANSFER BOX DESCRIPTION AND OPERATION 1 This page is intentionally left blank ...

  • Land Rover lt230t - page 15

    TRANSFER BOX 2 DESCRIPTION AND OPERATION ...

  • Land Rover lt230t - page 16

    TRANSFER BOX DESCRIPTION AND OPERATION 3 FRONT OUTPUT HOUSING COMPONENTS 1. High/low cross shaft housing 2. Bolt - high/low cross shaft housing 3. ’O’ ring 4. High/low cross shaft and lever 5. Dog clutch 6. Front output shaft 7. Hollow plug 8. Detent plug - differential lock 9. Detent spring - differential lock 10. Detent ball - differential lo ...

  • Land Rover lt230t - page 17

    TRANSFER BOX 4 DESCRIPTION AND OPERATION ...

  • Land Rover lt230t - page 18

    TRANSFER BOX DESCRIPTION AND OPERATION 5 DIFFERENTIAL COMPONENTS 1. Retaining ring 2. Differential carrier - rear half 3. Low range gear 4. High/low hub 5. High/low selector sleeve 6. High/low selector shaft 7. High/low selector fork 8. Setscrew - high/low selector fork 9. High range gear 10. High range gear bush 11. Differential rear bearing 12. B ...

  • Land Rover lt230t - page 19

    TRANSFER BOX 6 DESCRIPTION AND OPERATION ...

  • Land Rover lt230t - page 20

    TRANSFER BOX DESCRIPTION AND OPERATION 7 MAIN CASING COMPONENTS 1. Main casing 2. Retaining plate 3. Bolt - retaining plate 4. Stake nut - intermediate shaft 5. Bearings and outer tracks - mainshaft input gear 6. Mainshaft input gear * 7. Selective shim 8. Gasket ** 9. Mainshaft input gear bearing housing 10. Oil feed plate *** 11. ’O’ ring *** ...

  • Land Rover lt230t - page 21

    TRANSFER BOX 8 DESCRIPTION AND OPERATION ...

  • Land Rover lt230t - page 22

    TRANSFER BOX DESCRIPTION AND OPERATION 9 REAR OUTPUT HOUSING AND TRANSMISSION BRAKE COMPONENTS 1. Rear output shaft 2. Gasket * 3. Rear output housing 4. Bolt - rear output housing 5. Speedometer drive gear 6. Spacer 7. Output shaft bearing 8. Circlip 9. Oil seal 10. Mud shield 11. Output shaft flange 12. Felt washer 13. Steel washer 14. Self-locki ...

  • Land Rover lt230t - page 23

    TRANSFER BOX 10 DESCRIPTION AND OPERATION ...

  • Land Rover lt230t - page 24

    TRANSFER BOX DESCRIPTION AND OPERATION 11 TRANSFER BOX CROSS SECTION 1. Main casing 2. Front output housing 3. Rear output housing 4. Dog clutch 5. Transmission brake 6. Mainshaft input gear 7. Selective shim - input gear bearing pre-load 8. Intermediate gear cluster 9. Intermediate shaft 10. Collapsible spacer 11. Differential assembly 12. Selecti ...

  • Land Rover lt230t - page 25

    TRANSFER BOX 12 DESCRIPTION AND OPERATION Differential assembly The differential assembly is supported at the front and rear by taper roller bearings, the bearing outer tracks being located in the front and rear output housings. Bearing pre-load is achieved by means of a selective shim located in the front output housing. The differential rear shaf ...

  • Land Rover lt230t - page 26

    TRANSFER BOX DESCRIPTION AND OPERATION 13 OPERATION The gearbox output shaft transmits power to the mainshaft input gear which is in constant mesh with one of the intermediate gears. The intermediate gears are in constant mesh with the high and low range output gears running on the differential rear shaft. Power is transmitted to the output shafts ...

  • Land Rover lt230t - page 27

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  • Land Rover lt230t - page 28

    TRANSFER BOX OVERHAUL 1 TRANSFER BOX DISMANTLING 1. Clean exterior of transfer box. 2. Drain and discard the oil, refit drain plug. 3. Slacken bolt to release transmission brake adjustment. 4. Remove countersunk screw securing transmission brake drum, remove drum. NOTE: 2 screws may be fitted. 5. Make suitable alignment marks between transmission b ...

  • Land Rover lt230t - page 29

    TRANSFER BOX 2 OVERHAUL 11. Release staking from intermediate shaft nut, remove and discard nut. 12. Remove bolt securing anti-rotation plate, remove plate. 13. Using a soft metal drift on threaded end of intermediate shaft, drive shaft out of main casing. 14. Remove and discard ’O’ ring from intermediate shaft. 15. Remove and discard ’O’ r ...

  • Land Rover lt230t - page 30

    TRANSFER BOX OVERHAUL 3 NOTE: Discovery cover plate illustrated. 19. Make suitable alignment marks between cover plate/power take-off cover, mainshaft input gear bearing housing and main casing 20. Noting fitted position of stud nut and harness/speedometer cable clip, remove 5 bolts and stud nut securing cover plate/ power take-off cover, recover c ...

  • Land Rover lt230t - page 31

    TRANSFER BOX 4 OVERHAUL 27. Remove mainshaft input gear together with taper roller bearings. NOTE: Input gear fitted to Defender transfer boxes has an additional dog tooth gear - see inset on illustration. 28. Remove and discard mainshaft oil seal from main casing. CAUTION: Do not remove mainshaft input gear bearing track at this stage. 29. Remove ...

  • Land Rover lt230t - page 32

    TRANSFER BOX OVERHAUL 5 32. Slacken locknut and remove differential lock warning lamp switch from front output housing. 33. Noting fitted position of longest bolt, remove 8 bolts securing front output housing to main casing. 34. Remove front output housing. NOTE: Dowel located. 35. Up to serial no. 288709E: Remove and discard gasket. CAUTION: Do no ...

  • Land Rover lt230t - page 33

    TRANSFER BOX 6 OVERHAUL 39. Remove plug securing high/low selector shaft detent spring and ball. 40. Remove detent spring. 41. Remove ball using a stick magnet. CAUTION: Suitably identify plug, detent spring and ball to their fitted positions, do not interchange with differential lock selector shaft detent components. If fitted 42. Remove 4 bolts s ...

  • Land Rover lt230t - page 34

    TRANSFER BOX OVERHAUL 7 COMPONENT DISMANTLING High/low cross shaft housing 1. Slacken locknut and remove neutral warning lamp switch - Range Rover Classic only - if fitted. 2. Remove setscrew securing high/low selector finger to cross shaft. 3. Withdraw cross shaft from housing, recover high/low selector finger. 4. Remove and discard ’O’ ring. ...

  • Land Rover lt230t - page 35

    TRANSFER BOX 8 OVERHAUL 8. Compress differential lock selector fork spring and remove retaining clip from each end of spring. 9. Withdraw differential lock selector shaft from front output housing, recover spring. 10. Remove differential lock selector fork. 11. Position propeller shaft flange holding tool LRT-51-003 to output shaft flange. 12. Remo ...

  • Land Rover lt230t - page 36

    TRANSFER BOX OVERHAUL 9 15. Using a mallet, drive output shaft out of front output housing. NOTE: If it is necessary to use a hand press to remove output shaft, position thrust button LRT-370-11/2 between shaft and press mandrel. 16. Noting its fitted position, remove dog clutch from output shaft. 17. Noting its fitted position, remove bearing spac ...

  • Land Rover lt230t - page 37

    TRANSFER BOX 10 OVERHAUL 22. Invert front output housing. 23. Using a soft metal drift, drive differential bearing track out of housing, discard bearing track. 24. Remove selective shim. Rear output housing 1. Position propeller shaft flange holding tool LRT-51-003 to output shaft flange. 2. Remove and discard self-locking nut. 3. Remove steel and ...

  • Land Rover lt230t - page 38

    TRANSFER BOX OVERHAUL 11 5. Carefully lever speedometer driven gear and housing out of rear output housing. 6. Remove and discard ’O’ ring. 7. Withdraw speedometer driven gear from housing, remove and discard oil seal from housing. 8. Position rear output housing on bed of hand press. 9. Position thrust button LRT-37-11/2 between end of output ...

  • Land Rover lt230t - page 39

    TRANSFER BOX 12 OVERHAUL 12. Using a screwdriver inserted in slot in rear output housing, lever mud shield out of housing. CAUTION: Discard mud shield if it is damaged. 13. Taking care not to damage rear output housing, remove and discard output shaft oil seal. 14. Using suitable circlip pliers, remove and discard circlip retaining output shaft bea ...

  • Land Rover lt230t - page 40

    TRANSFER BOX OVERHAUL 13 Main casing 1. Support main casing on suitable blocks of wood. 2. Using a soft metal drift, drive differential rear bearing track out of main casing; discard bearing track. 3. Invert main casing. 4. Using a soft metal drift, drive mainshaft input gear bearing track out of main casing; discard bearing track. Mainshaft input ...

  • Land Rover lt230t - page 41

    TRANSFER BOX 14 OVERHAUL Intermediate gears 1. Secure intermediate gears in a soft-jawed vice. 2. Using a soft metal drift, drive intermediate shaft bearing track out of gears; discard bearing track. 3. Remove and discard circlip. 4. Repeat above procedure for remaining bearing track. Mainshaft input gear assembly NOTE: Defender input gear illustra ...

  • Land Rover lt230t - page 42

    TRANSFER BOX OVERHAUL 15 Differential lock selector 1. Remove and discard self-locking nut retaining selector lever. 2. Remove washer and selector lever. 3. Withdraw selector finger and shaft from housing. 4. Remove and discard ’O’ ring. Differential 1. Secure differential in a soft-jawed vice. 2. Remove staking from bearing retaining nut. 3. R ...

  • Land Rover lt230t - page 43

    TRANSFER BOX 16 OVERHAUL 4. Secure hand press LRT-99-002 in a vice. 5. Secure collars LRT-41-001 around rear bearing. NOTE: This bearing is adjacent to threaded end of differential shaft. 6. Position differential in hand press with thrust button, part of tool LRT-41-001 between press mandrel and differential shaft. 7. Press differential out of bear ...

  • Land Rover lt230t - page 44

    TRANSFER BOX OVERHAUL 17 12. Using a suitable puller and thrust button, part of tool LRT-41-001, remove high/low hub and low range gear. 13. Secure hand press LRT-99-002 in a vice. 14. Assemble collars LRT-41-002 around front bearing. NOTE: This bearing is adjacent to splined end of differential shaft. 15. Position differential in hand press with t ...

  • Land Rover lt230t - page 45

    TRANSFER BOX 18 OVERHAUL 18. Secure rear half of differential carrier in a soft-jawed vice. 19. Make suitable alignment marks between front and rear halves of differential carrier. 20. Remove 8 bolts securing front half of carrier to rear, remove carrier. 21. Suitably identify front sun gear to front half of carrier, remove sun gear. 22. Remove and ...

  • Land Rover lt230t - page 46

    TRANSFER BOX OVERHAUL 19 Intermediate gears and shaft 1. Check gear teeth for cracks, chipping and uneven wear. 2. Check shaft for wear and threads for damage. Mainshaft input gear 1. Check gear teeth for cracks, chipping and uneven wear. 2. Check that cross drillings in shaft are clear. NOTE: Early transfer boxes fitted with an oil feed plate do n ...

  • Land Rover lt230t - page 47

    TRANSFER BOX 20 OVERHAUL High/low cross shaft and housing 1. Check mating surfaces of cross shaft and drilling in housing for wear. 2. Check core plug in housing for signs of leakage or corrosion, apply Loctite 326 to replacement plug. 3. Check high/low selector finger for wear. 4. Measure across widest portion of finger: Finger width = 15.90 to 15 ...

  • Land Rover lt230t - page 48

    TRANSFER BOX OVERHAUL 21 6. Check detent grooves in differential lock selector shaft for wear. 7. Check differential lock detent ball for flat spots. 8. Check detent spring for distortion. 9. Check differential lock selector fork for cracks and wear. 10. Check differential lock selector fork finger width: Finger width = 7.92 to 7.97 mm (0.311 to 0. ...

  • Land Rover lt230t - page 49

    TRANSFER BOX 22 OVERHAUL 14. Check dog clutch selector fork groove width: Groove width = 8.05 to 8.20 mm (0.32 to 0.33 in) 15. Check threads and splines of output shaft for damage and wear. 16. Check dog clutch teeth on shaft for wear and damage. Rear output housing 1. Check bearing track recess in housing for damage, rectify or replace housing as ...

  • Land Rover lt230t - page 50

    TRANSFER BOX OVERHAUL 23 Main casing 1. Check bearing track recesses in main casing for damage, rectify or replace casing as necessary. 2. Remove drain plug, discard sealing washer. 3. Fit new sealing washer, fit drain plug and tighten to 30 Nm (22 lbf.ft). 4. Remove filler plug, check threads for damage. 5. Fit but do not fully tighten filler plug ...

  • Land Rover lt230t - page 51

    TRANSFER BOX 24 OVERHAUL High/low selector fork and shaft NOTE: There is no need to remove selector fork from shaft unless fork or shaft is to be replaced. If fork is removed, coat threads of setscrew with Loctite 290 prior to assembly. 1. Check detent grooves in shaft for wear. 2. Check high/low selector finger groove width in shaft: Groove width ...

  • Land Rover lt230t - page 52

    TRANSFER BOX OVERHAUL 25 Differential 1. Check sun and planet gears for wear, cracks and chipping of teeth. 2. Check cross shafts and recesses in both halves of differential carrier for damage and wear. CAUTION: Ensure planet gears are retained with their respective shafts. 3. Check retaining ring for distortion. 4. Check splines of differential sh ...

  • Land Rover lt230t - page 53

    TRANSFER BOX 26 OVERHAUL COMPONENT ASSEMBLING 1. Lubricate all components with recommended oil. Differential 1. Lightly oil threads of differential bolts. 2. Secure rear half of differential carrier in a soft-jawed vice. 3. Fit each planet gear to its respective cross-shaft, fit new dished thrust washer to each gear. 4. Fit cross-shafts, planet gea ...

  • Land Rover lt230t - page 54

    TRANSFER BOX OVERHAUL 27 15. If load to turn figure is below that specified, proceed as follows. 16. Remove front output shaft together with brake drum. 17. Remove 8 bolts securing front half differential carrier. 18. Remove front half differential carrier. 19. Remove front half carrier sun gear and thrust washer. 20. Select a thicker thrust washer ...

  • Land Rover lt230t - page 55

    TRANSFER BOX 28 OVERHAUL 36. Invert assembly in vice and then insert rear output shaft into rear half carrier, check that gears rotate freely. 37. Fit output flange on to splines of output shaft, do not fit flange nut at this stage. 38. Fit transmission brake drum to output flange, secure with 2 nuts. 39. Carry out load to turn check using same met ...

  • Land Rover lt230t - page 56

    TRANSFER BOX OVERHAUL 29 47. Support front half carrier in a soft-jawed vice. 48. Fit low range gear ensuring that dog teeth on gear are towards threaded end of shaft. NOTE: Use a suitable hollow mandrel to fit gear if it is tight on splines. 49. Fit high/low hub ensuring that alignment mark made during dismantling is towards threaded end of shaft. ...

  • Land Rover lt230t - page 57

    TRANSFER BOX 30 OVERHAUL 55. Slide high/low selector sleeve and hub away from low range gear. 56. Using feeler gauges, determine clearance between low range gear and high/low hub: Clearance = 0.05 to 0.15 mm (0.002 to 0.006 in) 57. If clearance is not as specified, fit a new low range gear and high/low hub and re-check. 58. Slide high/low selector ...

  • Land Rover lt230t - page 58

    TRANSFER BOX OVERHAUL 31 61. Using a round nosed punch, stake collar of nut into recess in differential shaft. Main casing 1. Fit a new differential rear bearing track using tool LRT-51-009. 2. Using a straight edge and feeler gauges, check that bearing track is recessed 1.0 mm (0.04 in) below outer face of main casing. 3. Using a suitable mandrel, ...

  • Land Rover lt230t - page 59

    TRANSFER BOX 32 OVERHAUL 4. Lubricate a new mainshaft oil seal with recommended oil. 5. Invert main casing and fit oil seal, lip side facing inwards, using tool LRT-37-014. Mainshaft input gear bearing housing 1. Ensure bearing track recess in housing is clean. 2. Position a 3.15 mm (0.12 in) thick shim in bearing housing. NOTE: This is the the thi ...

  • Land Rover lt230t - page 60

    TRANSFER BOX OVERHAUL 33 Mainshaft input gear assembly 1. Lubricate new bearings with recommended oil. 2. Secure hand press LRT-99-002 in a vice. 3. Position collars LRT-41-003 in hand press. 4. Position new bearing on collars. NOTE: Smallest diameter of bearing must be towards collars. 5. Locate end of mainshaft in bearing, press mainshaft through ...

  • Land Rover lt230t - page 61

    TRANSFER BOX 34 OVERHAUL Rear output housing 1. Heat rear output housing to 100 ° C (210 ° F). 2. Fit new output shaft bearing using tool LRT-41-011. 3. Allow housing to air cool. 4. Fit new bearing retaining circlip ensuring it is seated in groove. 5. Lubricate a new output shaft oil seal with recommended oil. 6. Fit oil seal using tool LRT-41-0 ...

  • Land Rover lt230t - page 62

    TRANSFER BOX OVERHAUL 35 9. Position rear output housing on bed of hand press. 10. Locate threaded end of output shaft in bearing. 11. Position thrust button LRT-37-11/2 between end of output shaft and press mandrel. 12. Press output shaft into bearing. 13. Fit mud shield with open face of shield towards oil seal. CAUTION: Do not fit output shaft f ...

  • Land Rover lt230t - page 63

    TRANSFER BOX 36 OVERHAUL 14. Fit speedometer driven gear into rear output housing ensuring that gear teeth are engaged with drive gear. 15. Lubricate a new ’O’ ring with recommended oil and fit to driven gear housing. 16. Fit driven gear housing. 17. Lubricate a new oil seal with recommended oil, fit seal with lip towards driven gear housing. F ...

  • Land Rover lt230t - page 64

    TRANSFER BOX OVERHAUL 37 5. Lubricate a new output shaft oil seal with recommended oil. 6. Fit oil seal using tool LRT-41-012. NOTE: Use end of tool marked ’FRONT’ to fit oil seal. 7. Check that oil seal is just contacting circlip. 8. Position selected shim in front output housing. 9. Fit differential front bearing track using tool LRT-54-003. ...

  • Land Rover lt230t - page 65

    TRANSFER BOX 38 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 to end of shaft. 5. Align hole in high/low selector finger w ...

  • Land Rover lt230t - page 66

    TRANSFER BOX OVERHAUL 39 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 ...

  • Land Rover lt230t - page 67

    TRANSFER BOX 40 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 was ...

  • Land Rover lt230t - page 68

    TRANSFER BOX OVERHAUL 41 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 ne ...

  • Land Rover lt230t - page 69

    TRANSFER BOX 42 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, tool LRT-41-014/2 and cross-bar, tool LRT-41-014/1 on front output housing. 14. Position DTI LRT-99-006 on cross-bar LRT-41-014/1 . 15. Zero DTI on depth block LRT-41-014/2 ...

  • Land Rover lt230t - page 70

    TRANSFER BOX OVERHAUL 43 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 e ...

  • Land Rover lt230t - page 71

    TRANSFER BOX 44 OVERHAUL 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 angl ...

  • Land Rover lt230t - page 72

    TRANSFER BOX OVERHAUL 45 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 differ ...

  • Land Rover lt230t - page 73

    TRANSFER BOX 46 OVERHAUL Intermediate gears 1. Insert a new collapsible spacer into intermediate gears, fit bearings into bearing tracks. 2. 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 ...

  • Land Rover lt230t - page 74

    TRANSFER BOX OVERHAUL 47 4. Raise intermediate gears until dummy shaft LRT-41-004 can be inserted from front output housing side of main casing. 5. 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. 6. Remove wire from around in ...

  • Land Rover lt230t - page 75

    TRANSFER BOX 48 OVERHAUL Intermediate gear bearing pre-load 1. Select neutral. 2. Screw a suitable bolt into tapped hole in end of tool LRT-41-005. 3. Insert tool LRT-41-005 in end of mainshaft. 4. Using a suitable torque meter on tool LRT-41-005, check and record torque to turn mainshaft input gears. 5. Tighten the intermediate shaft nut in small ...

  • Land Rover lt230t - page 76

    TRANSFER BOX OVERHAUL 49 All transfer boxes 13. Apply Hylosil RTV 102 sealant or position new, dry gasket to mating face of cover plate/power take-off cover. Position plate/cover on bearing housing ensuring that reference marks are aligned. 14. Position clip to stud nut. 15. Apply Loctite 290 to threads of bolts and stud nut. 16. Fit 5 bolts and st ...

  • Land Rover lt230t - page 77

    TRANSFER BOX 50 OVERHAUL High/low selector shaft detent 1. Fit detent ball and spring. 2. Apply Loctite 290 to threads of detent plug. 3. Fit and tighten plug then unscrew 2 full turns. 4. Operate high/low selector lever and check that detent ball can be felt to positively engage and disengage with grooves in selector shaft; screw plug in or out un ...

  • Land Rover lt230t - page 78

    TRANSFER BOX OVERHAUL 51 Neutral warning lamp switch - if fitted - not Range Rover Classic 1. Apply Hylosil PL32 sealant to threads of switch. 2. Fit washer, fit and tighten switch. Differential lock warning lamp switch - adjust 1. Move differential lock selector fork to differential locked position. 2. Connect a 12V test lamp and battery to differ ...

  • Land Rover lt230t - page 79

    TRANSFER BOX 52 OVERHAUL Transmission brake 1. Apply Hylosil RTV 102 sealant to mating face of rear output housing. 2. Position brake backplate on rear output housing ensuring that alignment marks are together. 3. Fit 4 bolts and tighten to 70 Nm (52 lbf.ft). 4. Fit transmission brake drum, fit countersunk screw and tighten. NOTE: Early transfer bo ...

  • Land Rover lt230t - page 80

    TRANSFER BOX DATA, TORQUE & TOOLS 1 DATA High/low selector finger width 15.90 to 15.95 mm .................. 0.625 to 0.627 in High/low selector fork finger width 7.37 to 7.47 mm ............... 0.290 to 0.294 in High/low selector shaft groove width 16.0 to 16.1 mm ............. 0.63 to 0.64 in High/low selector hub groove width 7.5 to 7.6 mm . ...

  • Land Rover lt230t - page 81

    TRANSFER BOX 2 DATA, TORQUE & TOOLS TORQUE FIGURES Drain plug 30 Nm ................................. 2 2 lbf.ft Differential carrier bolts 60 Nm ....................... 4 4 lbf.ft Differential bearing nut 72 Nm ....................... 5 3 lbf.ft Differential lock selector lever nut 15 Nm ............... 1 1 lbf.ft * Front and rear output housi ...

  • Land Rover lt230t - page 82

    TRANSFER BOX DATA, TORQUE & TOOLS 3 SERVICE TOOLS LRT-37-11/2 Thrust button LRT-37-014 Mainshaft oil seal replacer LRT-41-001 Collars - differential rear bearing LRT-41-001 Thrust button LRT-41-002 Collars - differential front bearing LRT-41-003 Mainshaft input gear bearing remover/replacer LRT-41-004 Intermediate gear dummy shaft LRT-41-005 In ...

Manufacturer Land Rover Category Automobile Parts

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