Land Rover lt230t User Manual

Overhaul Manual LT230TVerdeelbak revisieboekLT230TBoîte de transfert Manuel de révisionLT230TVerteilergetriebe ÜberholungsanleitungLT230TRiduttore Man

TRANSFER BOXCONTENTSPageDESCRIPTION AND OPERATIONFRONT OUTPUT HOUSING COMPONENTS 3...DIFFERENTIA

TRANSFER BOXCONTENTSPageNeutral warning lamp switch - if fitted - not Range Rover Classic 51...Differential lock warning lamp

TRANSFER BOXCONTENTSPageDATA, TORQUE & TOOLSDATA 1...

TRANSFER BOXDESCRIPTION AND OPERATION 1This page is intentionally left blank

TRANSFER BOX2DESCRIPTION AND OPERATION

TRANSFER BOXDESCRIPTION AND OPERATION 3FRONT OUTPUT HOUSING COMPONENTS1. High/low cross shaft housing2. Bolt - high/low cross shaft housing3. ’O’ ring

TRANSFER BOX4DESCRIPTION AND OPERATION

TRANSFER BOXDESCRIPTION AND OPERATION 5DIFFERENTIAL COMPONENTS1. Retaining ring2. Differential carrier - rear half3. Low range gear4. High/low hub5. H

TRANSFER BOX6DESCRIPTION AND OPERATION

Dealer StampTechnical Information ReviewWhile every attempt is made to ensure that the technical information we supply is as accurate and up to date a

TRANSFER BOXDESCRIPTION AND OPERATION 7MAIN CASING COMPONENTS1. Main casing2. Retaining plate3. Bolt - retaining plate4. Stake nut - intermediate shaf

TRANSFER BOX8DESCRIPTION AND OPERATION

TRANSFER BOXDESCRIPTION AND OPERATION 9REAR OUTPUT HOUSING AND TRANSMISSIONBRAKE COMPONENTS1. Rear output shaft2. Gasket *3. Rear output housing4. Bol

TRANSFER BOX10DESCRIPTION AND OPERATION

TRANSFER BOXDESCRIPTION AND OPERATION 11TRANSFER BOX CROSS SECTION1. Main casing2. Front output housing3. Rear output housing4. Dog clutch5. Transmiss

TRANSFER BOX12DESCRIPTION AND OPERATIONDifferential assemblyThe differential assembly is supported at the frontand rear by taper roller bearings, the

TRANSFER BOXDESCRIPTION AND OPERATION 13OPERATIONThe gearbox output shaft transmits power to themainshaft input gear which is in constant mesh withone

TRANSFER BOXOVERHAUL 1TRANSFER BOX DISMANTLING1. Clean exterior of transfer box.2. Drain and discard the oil, refit drain plug.3. Slacken bolt to rele

TRANSFER BOX2OVERHAUL11. Release staking from intermediate shaft nut,remove and discard nut.12. Remove bolt securing anti-rotation plate,remove plate.

TRANSFER BOXOVERHAUL 3NOTE: Discovery cover plate illustrated.19. Make suitable alignment marks between coverplate/power take-off cover, mainshaft inp

TRANSFER BOX4OVERHAUL27. Remove mainshaft input gear together withtaper roller bearings.NOTE: Input gear fitted to Defendertransfer boxes has an addit

TRANSFER BOXOVERHAUL 532. Slacken locknut and remove differential lockwarning lamp switch from front output housing.33. Noting fitted position of long

TRANSFER BOX6OVERHAUL39. Remove plug securing high/low selector shaftdetent spring and ball.40. Remove detent spring.41. Remove ball using a stick mag

TRANSFER BOXOVERHAUL 7COMPONENT DISMANTLINGHigh/low cross shaft housing1. Slacken locknut and remove neutral warninglamp switch - Range Rover Classic

TRANSFER BOX8OVERHAUL8. Compress differential lock selector fork springand remove retaining clip from each end ofspring.9. Withdraw differential lock

TRANSFER BOXOVERHAUL 915. Using a mallet, drive output shaft out of frontoutput housing.NOTE: If it is necessary to use a handpress to remove output s

TRANSFER BOX10OVERHAUL22. Invert front output housing.23. Using a soft metal drift, drive differentialbearing track out of housing, discard bearingtra

TRANSFER BOXOVERHAUL 115. Carefully lever speedometer driven gear andhousing out of rear output housing.6. Remove and discard ’O’ ring.7. Withdraw spe

TRANSFER BOX12OVERHAUL12. Using a screwdriver inserted in slot in rearoutput housing, lever mud shield out ofhousing.CAUTION: Discard mud shield if it

LT230TTRANSFER BOXOVERHAULMANUALThis transfer box is fitted to the following models:Serial No. Prefixes 20D, 22D and 32D - DefenderSerial No. Prefixes

TRANSFER BOXOVERHAUL 13Main casing1. Support main casing on suitable blocks ofwood.2. Using a soft metal drift, drive differential rearbearing track o

TRANSFER BOX14OVERHAULIntermediate gears1. Secure intermediate gears in a soft-jawed vice.2. Using a soft metal drift, drive intermediate shaftbearing

TRANSFER BOXOVERHAUL 15Differential lock selector1. Remove and discard self-locking nut retainingselector lever.2. Remove washer and selector lever.3.

TRANSFER BOX16OVERHAUL4. Secure hand press LRT-99-002 in a vice.5. Secure collars LRT-41-001 around rearbearing.NOTE: This bearing is adjacent tothrea

TRANSFER BOXOVERHAUL 1712. Using a suitable puller and thrust button, partof tool LRT-41-001, remove high/low hub andlow range gear.13. Secure hand pr

TRANSFER BOX18OVERHAUL18. Secure rear half of differential carrier in asoft-jawed vice.19. Make suitable alignment marks between frontand rear halves

TRANSFER BOXOVERHAUL 19Intermediate gears and shaft1. Check gear teeth for cracks, chipping anduneven wear.2. Check shaft for wear and threads for dam

TRANSFER BOX20OVERHAULHigh/low cross shaft and housing1. Check mating surfaces of cross shaft anddrilling in housing for wear.2. Check core plug in ho

TRANSFER BOXOVERHAUL 216. Check detent grooves in differential lockselector shaft for wear.7. Check differential lock detent ball for flat spots.8. Ch

TRANSFER BOX22OVERHAUL14. Check dog clutch selector fork groove width:Groove width = 8.05 to 8.20 mm (0.32 to 0.33in)15. Check threads and splines of

TRANSFER BOXOVERHAUL 23Main casing1. Check bearing track recesses in main casingfor damage, rectify or replace casing asnecessary.2. Remove drain plug

TRANSFER BOX24OVERHAULHigh/low selector fork and shaftNOTE: There is no need to removeselector fork from shaft unless fork orshaft is to be replaced.

TRANSFER BOXOVERHAUL 25Differential1. Check sun and planet gears for wear, cracksand chipping of teeth.2. Check cross shafts and recesses in bothhalve

TRANSFER BOX26OVERHAULCOMPONENT ASSEMBLING1. Lubricate all components with recommendedoil.Differential1. Lightly oil threads of differential bolts.2.

TRANSFER BOXOVERHAUL 2715. If load to turn figure is below that specified,proceed as follows.16. Remove front output shaft together with brakedrum.17.

TRANSFER BOX28OVERHAUL36. Invert assembly in vice and then insert rearoutput shaft into rear half carrier, check thatgears rotate freely.37. Fit outpu

TRANSFER BOXOVERHAUL 2947. Support front half carrier in a soft-jawed vice.48. Fit low range gear ensuring that dog teeth ongear are towards threaded

TRANSFER BOX30OVERHAUL55. Slide high/low selector sleeve and hub awayfrom low range gear.56. Using feeler gauges, determine clearancebetween low range

TRANSFER BOXOVERHAUL 3161. Using a round nosed punch, stake collar of nutinto recess in differential shaft.Main casing1. Fit a new differential rear b

TRANSFER BOX32OVERHAUL4. Lubricate a new mainshaft oil seal withrecommended oil.5. Invert main casing and fit oil seal, lip sidefacing inwards, using

INTRODUCTIONCONTENTSPageINFORMATIONINTRODUCTION 1...

TRANSFER BOXOVERHAUL 33Mainshaft input gear assembly1. Lubricate new bearings with recommended oil.2. Secure hand press LRT-99-002 in a vice.3. Positi

TRANSFER BOX34OVERHAULRear output housing1. Heat rear output housing to 100 °C (210 °F).2. Fit new output shaft bearing using toolLRT-41-011.3. Allow

TRANSFER BOXOVERHAUL 359. Position rear output housing on bed of handpress.10. Locate threaded end of output shaft in bearing.11. Position thrust butt

TRANSFER BOX36OVERHAUL14. Fit speedometer driven gear into rear outputhousing ensuring that gear teeth are engagedwith drive gear.15. Lubricate a new

TRANSFER BOXOVERHAUL 375. Lubricate a new output shaft oil seal withrecommended oil.6. Fit oil seal using tool LRT-41-012.NOTE: Use end of tool marked

TRANSFER BOX38OVERHAULHigh/low cross shaft housing1. Lubricate cross shaft and new ’O’ ring withrecommended oil.2. Insert cross shaft into housing, po

TRANSFER BOXOVERHAUL 39TRANSFER BOX ASSEMBLING1. Lubricate all components with recommendedoil.CAUTION: Where use of gaskets isspecified, gaskets must

TRANSFER BOX40OVERHAULRear output housing1.Up to serial no. 288709E:Position a newgasket, dry on main casing.2.From serial no. 288709E:Apply Hylosil R

TRANSFER BOXOVERHAUL 41Differential bearing pre-load1. Position high/low selector shaft and fork todifferential ensuring that fingers of selector fork

TRANSFER BOX42OVERHAUL11. Position front output housing as shown.12.Up to serial no. 288709E:Position a newgasket, dry, on front output housing.13. Po

TRANSFER BOXOVERHAUL 43Front output housing1.Up to serial no. 288709E:Fit gasket usedwhen determining differential bearing pre-load,dry, to main casin

TRANSFER BOX44OVERHAUL10. Compress differential lock selector spring andfit to selector fork.11. Locate fingers of selector fork in groove in dogclutc

TRANSFER BOXOVERHAUL 4518. Ensure ’O’ ring is correctly located ondifferential lock selector housing.19. Fit differential lock selector assembly ensur

TRANSFER BOX46OVERHAULIntermediate gears1. Insert a new collapsible spacer intointermediate gears, fit bearings into bearingtracks.2. Wrap a suitable

TRANSFER BOXOVERHAUL 474. Raise intermediate gears until dummy shaftLRT-41-004 can be inserted from front outputhousing side of main casing.5. Fit int

TRANSFER BOX48OVERHAULIntermediate gear bearing pre-load1. Select neutral.2. Screw a suitable bolt into tapped hole in end oftool LRT-41-005.3. Insert

TRANSFER BOXOVERHAUL 49All transfer boxes13. Apply Hylosil RTV 102 sealant or position new,dry gasket to mating face of cover plate/powertake-off cove

TRANSFER BOX50OVERHAULHigh/low selector shaft detent1. Fit detent ball and spring.2. Apply Loctite 290 to threads of detent plug.3. Fit and tighten pl

TRANSFER BOXOVERHAUL 51Neutral warning lamp switch - if fitted - notRange Rover Classic1. Apply Hylosil PL32 sealant to threads ofswitch.2. Fit washer

TRANSFER BOX52OVERHAULTransmission brake1. Apply Hylosil RTV 102 sealant to mating faceof rear output housing.2. Position brake backplate on rear outp

INTRODUCTIONINTRODUCTION 1INTRODUCTIONHow to use this manualTo assist in the use of this manual the section title isgiven at the top and the relevant

TRANSFER BOXDATA, TORQUE & TOOLS 1DATAHigh/low selector finger width 15.90 to 15.95 mm... 0.625 to 0.627 inHigh/low selector fork f

TRANSFER BOX2DATA, TORQUE & TOOLSTORQUE FIGURESDrain plug 30 Nm... 22lbf.ftDifferential carrier bolts 60 Nm...

TRANSFER BOXDATA, TORQUE & TOOLS 3SERVICE TOOLSLRT-37-11/2 Thrust buttonLRT-37-014 Mainshaft oil seal replacerLRT-41-001 Collars - differential re

INTRODUCTION2INTRODUCTIONREPAIRS AND REPLACEMENTSWhen replacement parts are required it is essentialthat only Land Rover recommended parts are used.At