Home

Land Rover lt230t User's Manual

1. Apply Loctite 290 to threads 2 DATA TORQUE amp TOOLS 22 44 53 11 18 120 18 18 18 18 18 52 lbf ft 8 SERVICE TOOLS LRT 37 11 2 LRT 37 014 LRT 41 001 LRT 41 001 LRT 41 002 LRT 41 003 LRT 41 004 LRT 41 005 LRT 41 006 LRT 41 007 LRT 41 008 LRT 41 011 LRT 41 012 LRT 41 014 1 LRT 41 014 2 LRT 41 014 3 LRT 41 014 4 LRT 51 003 LRT 51 009 LRT 54 003 LRT 99 002 LRT 99 003 LRT 99 006 TRANSFER BOX 10 0 Thrust button Mainshaft oil seal replacer Collars differential rear bearing Thrust button Collars differential front bearing Mainshaft input gear bearing remover replacer Intermediate gear dummy shaft Input gear mandrel Intermediate gear bearing track replacer Differential bearing nut remover replacer Differential bearing replacer Output shaft bearing replacer Output shaft oil seal replacer Cross bar Depth block Setting block Pillar Propeller shaft flange holding tool Differential rear bearing track replacer Differential front bearing track replacer Hand press Driver handle Dial test indicator DATA TORQUE amp TOOLS 3
2. Intermediate gear bearing pre load An increase on mainshaft input gear initial torque to turn of TRANSFER BOX 10 0 15 90 to 15 95 mm 7 37 to 7 47 mm 16 0 to 16 1 mm 7 5 to 7 6 mm 15 90 to 15 95 mm 16 0 to 16 1 7 92 to 7 9 84 58 mm 8 05 to 8 20 mm 1 72 kg 1 05 to 1 45 mm 0 10 mm 3 44 kg 0 05 to 0 15 mm 0 05 to 0 15 m 0 05 mm 3 15 to 4 00 mm 0 05 mm 0 05 mm 2 00 to 3 25 mm 0 05 mm 0 625 to 0 627 in 0 290 to 0 294 in 0 63 to 0 64 in 0 295 to 0 30 in 0 625 to 0 627 in 0 63 to 0 64 in 0 311 to 0 313 in 3 33 in 0 32 to 0 33 in 1 0 lb 3 8 lb 0 04 to 0 06 in 0 004 in 2 0 lb 7 6 lb 0 002 to 0 006 in 0 002 to 0 006 in 0 002 in 0 12 to 0 16 in 0 002 in 0 002 in 0 08 to 0 13 in 0 002 in 10 Ibf in DATA TORQUE 8 TOOLS 1 TRANSFER BOX TORQUE FIGURES plug ii Vl es Differential carrier bolts Differential bearing nut Differential lock selector lever nut Front and rear output housing bolts Output flange nuts Differential lock selector housing bolts High low selector housing bolts Intermediate shaft retaining plate bolt Bottom cover bolts Bearing housing cover plate bolts and stud nut Transmission brake backplate bolts Interlock solenoid cover bolts if fitted
3. LRT 41 011 2 4 CS LAS 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 fully seated in groove 5 Lubricate a new output shaft oil seal with recommended oil LRT 41 012 41M7151 I 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 LRT 54 003 41M7152 9 Fit differential front bearing track using tool LRT 54 003 TRANSFER BOX 41M7153 10 Fit bearing spacer to output shaft ensuring that chamfer on spacer is towards threaded end of shaft 11 Fit dog clutch ensuring that flange on clutch is towards splined end of shaft 12 Using a mallet drive output shaft into bearing OVERHAUL 37 TRANSFER BOX High low cross shaft housing Differential lock selector 1 Lubricate cross shaft and new ring with 38 recommended oil 41M7154 Insert cross shaft into housing position high low selector finger on E OT ring to shaft locate end of shaft in hollow plug Slide O ring to end of shaft Align hole in high low selector finger with recess in cross shaft Apply Loctite 290 to threads of setscrew fit and tighten screw Apply Hylomar PL32 sealant to threads of neutral warning lamp s
4. LT230T TRANSFER GEARBOX Overhaul Manual LT230T Verdeelbak revisieboek LT230T Bo te de transfert Manuel de r vision LT230T Verteilergetriebe Uberholungsanleitung LT230T Riduttore Manvale di revisione LT230T Caja de transferencia anual de revisi n LT230T Caixa de velocidades manual Manual de revis o LAND 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 to improve the quality of our publications and invite you to submit details of any technical errors or improvements you would like to see in the space below Publication part number and edition Publication title Section and or pages aliected 0 geet Technical information errors Other improvements changes you would like us to consider Dealer Stamp Please return to Technical Communication Rover Group After Sales PO BOX 29 Cowley Oxford OX4 5NL 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
5. 3 Allow housing to air cool 4 Fit new bearing retaining circlip ensuring it is seated in groove 34 OVERHAUL 5 Lubricate a new output shaft oil seal with recommended oil 41M7145 6 Fit oil seal using tool LRT 41 012 NOTE Use end of tool marked REAR to EN fit oil seal 7 Check that oil seal is just contacting circlip 41M7146 8 Slide speedometer drive gear and spacer on to output shaft LRT 37 11 2 41M7147 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 TRANSFER BOX 10 0 13 Fit mud shield with open face of shield towards oil seal CAUTION Do not fit output shaft flange at this stage OVERHAUL 35 TRANSFER BOX 14 15 16 17 36 Fit speedometer driven gear into rear output housing ensuring that gear teeth are engaged with drive gear Lubricate a new ring with recommended oil and fit to driven gear housing Fit driven gear housing Lubricate a new oil seal with recommended oil fit seal with lip towards driven gear housing OVERHAUL Front output housing CAUTION Do not carry out assembly operations until differential bearing pre load has been established See Differential bearing pre load 1 Heat front output housing to 100 210 F
6. TRANSFER BOX Gel 41M7121 Check differential lock selector fork finger width Finger width 7 92 to 7 97 mm 0 311 to 0 313 in Check differential lock selector fork spring for distortion and clips for wear and damage Check spring free length Free length 84 58 mm 3 33 in Check dog clutch internal teeth and grooves for wear and damage OVERHAUL 21 TRANSFER BOX 14 15 16 22 5 Check dog clutch selector fork groove width Groove width 8 05 to 8 20 mm 0 32 to 0 33 in 41M7122 Check threads and splines of output shaft for damage and wear Check dog clutch teeth on shaft for wear and damage OVERHAUL Rear output housing 1 Check bearing track recess in housing for damage rectify or replace housing as necessary Check speedometer drive and driven gears for damage and wear Check splines and threads of output shaft for damage and wear TRANSFER BOX 10 0 Main casing Mainshaft input gear bearing housing 1 Check bearing track recesses in main casing 1 Check bearing track recess in housing for for damage rectify or replace casing as damage rectify or replace housing as necessary necessary 41M7123A 2 Remove drain plug discard sealing washer 3 Fit new sealing washer fit drain plug and tighten to 30 Nm 22 lbf ft Remove filler plug check threads for damage Fit but do not fully tighten filler plug Check that locating dowels are fitted
7. X we 41M7354 55 CV C Fit detent ball and spring Apply Loctite 290 to threads of detent plug Fit and tighten plug then unscrew 2 full turns 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 until setting is correct OVERHAUL Interlock solenoid if fitted 41 7355 Position interlock solenoid in main casing Apply Hylosil RTV 102 to mating face of solenoid cover Fit solenoid cover and Belleville washer fit bolts and tighten to 10 Nm 8 lbf ft TRANSFER BOX 10 0 Neutral warning lamp switch if fitted not Differential lock warning lamp switch adjust Range Rover Classic 41M7356 1 Apply Hylosil PL32 sealant to threads of switch 2 Fit washer fit and tighten switch 41M7177 1 Move differential lock selector fork to differential locked position 2 Connect a 12V test lamp and battery to differential lock switch 3 Screw switch in until test lamp is illuminated then screw switch in a further 1 2 turn tighten locknut 4 Disengage differential lock check that test lamp is extinguished 5 Remove test lamp 6 Up to serial no 288709E Apply grease to a new gasket and fit to differential lock side cover 7 From serial no 288709E Apply Hylosil RTV 102 sealant to mating face of differential lock side cover 8
8. components being secured to the shaft by a special nut The differential assembly comprises front and rear half carriers with integral shafts and sun and planet gears mounted on cross shafts within the half carriers Dished non selective thrust washers control the engagement of the planet gears with the sun gears whilst selective thrust washers are used to control the engagement of the sun gears and load to turn of the differential The differential carrier halves are bolted together a retaining ring providing positive location of the cross shafts The high low selector shaft and fork are located at the side of the differential movement of the shaft fork and selector sleeve being controlled by the high low selector finger A spring loaded detent ball fitted in the main casing locates in grooves in the shaft For certain markets a neutral warning lamp switch operated by the high low selector shaft and an interlock solenoid are fitted in the main casing 12 DESCRIPTION AND OPERATION Front output housing assembly The front output shaft is supported in the front output housing by a single bearing and is splined into the differential front shaft The high low cross shaft is located in a housing bolted to the top of the output housing and is connected to the high low selector finger which locates in a slot in the selector shaft The differential lock selector housing is also bolted to the top of the front output housing the
9. 14D 15D 20D 26D 27D 28D and 30D Range Rover Classic Publication Part No LRL 0081ENG 2nd Edition Published by Rover Technical Communication 1997 Rover Group Limited LAND ROVER INTRODUCTION CONTENTS Page INFORMATION INTRODUCTION 1 REPAIRS AND REPLACEMENTS Gh 2 SPECIFICATION EEN 2 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 atthe 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 e Description and Operation e 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
10. Fit side cover fit bolts and tighten to 25 Nm 18 lbf ft OVERHAUL 51 TRANSFER BOX Transmission brake 1 Apply Hylosil RTV 102 sealant to mating face of rear output housing SS 41M7178 2 Position brake backplate on rear output housing ensuring that alignment marks are together 3 Fit 4 bolts and tighten to 70 Nm 52 Ibf ft 4 Fit transmission brake drum fit countersunk screw and tighten NOTE Early transfer boxes 2 screws are fitted 52 OVERHAUL DATA High low selector finger width High low selector fork finger width High low selector shaft groove width High low selector hub groove width Differential lock selector finger width Differential lock selector shaft groove width Differential lock selector fork finger width Differential lock selector spring free length Dog clutch selector fork groove width Differential front and rear half carrier gears load to turn Used gears New gears Thrust washer thicknesses available In increments of Total load to turn both sun gears fitted Used gears New gears Low range gear to high range hub clearance High range gear to high low hub clearance Mainshaft input gear bearing pre load Mainshaft input gear bearing shim thicknesses available In increments of Differential bearing pre load Differential shim thicknesses available In increments
11. Lee 7 Rear outputine sindg lt lt ____ __ __ _ ___ _ 10 Mal CASING 13 Mainshaft input gear bearing 13 Intermediate tidad ide 14 Mainshaft input gear assembly 14 Differential _ 15 TT 15 INSPECTING COMPONENTS cnn 18 Intermediate gears and Shaft 2 19 19 High low cross shaft and housing nnn nnen eneen 20 Front output housing and differential lock 20 Rear outputiho sng Armenen dee ARR eha 22 M T 23 Mainshaft input gear bearing 0 23 High low selector fork and 24 __ _______ ___ _ _ _ _ __ _ 25 COMPONENT ASSEMBLING 26 Aur TEE 26 cu tirada adds dida 31 Mainshaft input gear bearing 32 Mainshaft input gear assembly 33 Intermediate TC 33 Rear output housing zn ant Ai et ate tea 34 Front OULpULINOUSING 36 High
12. 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 spacer from output shaft 41M7093 20 Support front output housing on suitable blocks of wood 21 Using a soft metal drift drive output shaft bearing out of housing discard bearing 41M7091 18 Taking care not to damage front output housing remove and discard output shaft oil seal OVERHAUL 9 TRANSFER BOX Rear output housing LRT 51 003 Sg 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 1 Position propeller shaft flange holding tool LRT 51 003 to output shaft flange 2 Remove and discard self locking nut 41M7096 3 Remove steel and felt washers discard felt washer 4 Remove output shaft flange together with circlip NOTE A replacement output flange will be supplied together with new output shaft oil seal 10 OVERHAUL 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 11 T
13. 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 INTRODUCTION 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 1 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
14. seated in recess in clips OVERHAUL 41M7163 Fit differential lock detent ball and spring Apply Loctite 290 to threads of detent plug Fit and tighten detent plug then unscrew 2 full turns 18 19 20 Fit bolts and tighten to 25 Nm 18 22 23 22 22 Z 23 41M7164 Ensure O ring is correctly located on differential lock selector housing Fit differential lock selector assembly ensuring that selector finger is located in recess in differential lock selector shaft Apply Loctite 290 to threads of bolts 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 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 do not tighten locknut or fit differential lock side cover until switch has been adjusted 24 25 26 27 TRANSFER BOX 0 0 Up to serial 288709E Apply grease to new high low selector housing gasket position gasket on front output housing From serial no 288709E Apply Hylosil RTV 102 sealant to mating flange of high low selector housing Fit housing ensuring that high low selector finger 15 located in recess in high low selector Fit 6 bolts
15. stake nut at this stage A OVERHAUL 29 TRANSFER BOX 55 56 57 30 41M7135 Slide high low selector sleeve and hub away from low range gear 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 If clearance is not as specified fit a new low range gear and high low hub and re check 58 59 60 41 7136 Slide high low selector sleeve and hub away from high range gear Using feeler gauges determine clearance between high range gear and high low hub Clearance 0 05 to 0 15 mm 0 002 to 0 006 in If clearance 15 not as specified fit new high range gear and high low hub and re check OVERHAUL TRANSFER BOX Main casing LRT 51 009 41M7138 41M7137 1 Fita new differential rear bearing track using tool LRT 51 009 61 Using a round nosed punch stake collar of nut 2 Using a straight edge and feeler gauges check into recess in differential that bearing track is recessed 1 0 mm 0 04 in below outer face of main casing 41M7139 3 Using a suitable mandrel fit a new mainshaft input gear bearing track CAUTION Ensure bearing tracks are AN seated squarely in recesses OVERHAUL 31 4 Lubricate a new mainshaft oil seal with recommended oil LRT 37 014 41M7140 EE 5 Invert main casing and fit oil seal lip side facing inwards using tool LRT 37 014 32 OVERH
16. AUL TRANSFER BOX Mainshaft input gear bearing housing 1 Ensure bearing track recess in housing 15 clean 41M7141 2 Position a 3 15 mm 0 12 in thick shim in bearing housing NOTE This is the the thinnest of the EN shims available 3 Using a suitable mandrel fit new mainshaft input gear bearing track CAUTION Ensure bearing track is seated squarely in recess TRANSFER BOX 10 0 Mainshaft input gear assembly 1 Lubricate new bearings with recommended oil 41M7142 LRT 41 003 LRT 99 002 Secure hand press LRT 99 002 in a vice Position collars LRT 41 003 in hand press Position new bearing on collars NOTE Smallest diameter of bearing must be towards collars 5 Locate end of mainshaft in bearing press mainshaft through bearing 6 Repeat above procedure for remaining bearing Intermediate gears 1 Lubricate new bearings and bearing tracks with recommended oil LRT 99 003 LRT 41 006 41M7143 2 Fit new circlips into intermediate gears CAUTION Ensure that circlips are AN correctly seated 3 Fit new bearing tracks using tools LRT 41 006 and LRT 99 003 CAUTION Ensure bearing tracks are fully AN seated against circlips 4 Retain bearings with intermediate gears OVERHAUL 33 TRANSFER BOX Rear output housing 1 Heat rear output housing to 100 C 210 F LRT 41 011 2 Fit new output shaft bearing using tool LRT 41 011
17. RANSFER BOX 0 0 37 11 2 41 7099 Position rear output housing on bed of hand press Position thrust button LRT 37 11 2 between end of output shaft and press mandrel Press output shaft out of housing 41 7100 Recover spacer and speedometer drive gear from output shaft OVERHAUL 11 TRANSFER BOX 41M7101 12 Using a screwdriver inserted in slot in rear output housing lever mud shield out of housing CAUTION Discard mud shield if it is A damaged 41M7102 13 Taking care not to damage rear output housing remove and discard output shaft oil seal 12 OVERHAUL 41M7103 14 Using suitable circlip pliers remove and discard circlip retaining output shaft bearing 41M7104 15 Support rear output housing on suitable blocks of wood 16 Using a soft metal drift drive output shaft bearing out of housing discard bearing Main casing 41M7105 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 41M7106 3 Invert main casing 4 Using a soft metal drift drive mainshaft input gear bearing track out of main casing discard bearing track TRANSFER BOX 0 0 Mainshaft input gear bearing housing 41M7107 Secure mainshaft input gear bearing housing in a soft jawed vice Using a soft metal drift drive input gear bearin
18. and tighten to 25 Nm 18 Ibf ft OVERHAUL 45 TRANSFER BOX Intermediate gears 41M7169 1 Insert a new collapsible spacer into intermediate gears fit bearings into bearing tracks 41M7171 3 Lubricate new O rings with recommended oil and fit to intermediate shaft and main casing Dee SS 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 A stage 46 OVERHAUL 41M7172 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 TRANSFER BOX 10 0 6 Remove wire from around intermediate gears NS 41 7173 10 7 9 7 Rotate intermediate shaft until retaining plate can be located on flat on shaft 8 Apply Loctite 290 to threads of retaining plate bolt 9 Fit bolt and tighten to 25 Nm 18 lbf ft 10 Fit a new intermediate shaft nut 11 Tighten intermediate shaft nut in small stages until all end float is removed from intermediate gears CAUTION Check end float of intermediate gears between each stage do not continue tightening nut after end flo
19. ase staking from intermediate shaft nut remove and discard nut Remove bolt securing anti rotation plate remove plate 41M7069 Using a soft metal drift on threaded end of intermediate drive shaft out of main casing Remove and discard ring from intermediate shaft Remove and discard O ring from main casing OVERHAUL 16 17 18 A Wrap a suitable length of wire around intermediate gears and using assistance lift gears out of main casing 41 7071 Remove and discard 2 taper roller bearings from intermediate gears Remove and discard collapsible spacer from intermediate gears CAUTION Do not remove bearing tracks at this stage TRANSFER BOX 0 0 24 24 41M7072A 41M7073A 24 Remove 2 countersunk screws if fitted NOTE Discovery cover plate illustrated securing mainshaft input gear bearing housing 25 Up to serial 288709 Remove mainshaft input gear bearing housing remove and 19 Make suitable alignment marks between cover discard gasket plate power take off cover mainshaft input gear bearing housing and main casing CAUTION Do not remove mainshaft input 20 Noting fitted position of stud nut and ZN gear bearing track at this stage harness speedometer cable clip remove 5 bolts and stud nut securing cover plate power take off cover recover clip 21 Remove cover plate power take off cover 22 Up to serial no 288709E Remove a
20. at is removed Do not stake nut at this stage 12 Set intermediate gear bearing pre load See Intermediate gear bearing pre load OVERHAUL 47 TRANSFER BOX Intermediate gear bearing pre load 1 Select neutral 2 Screw a suitable bolt into tapped hole in end of tool LRT 41 005 Y 41M7360 3 Insert tool LRT 41 005 in end of mainshaft 4 Using a suitable torque meter tool LRT 41 005 check and record torque to turn mainshaft input gears 5 Tighten the intermediate shaft nut in small stages checking the torque to turn the input gears until the mainshaft input gear torque to turn figure recorded in operation 4 has increased by 1 25 Nm 10 Ibf in CAUTION Take great care not to overtighten nut as this will cause excessive bearing pre load If torque to turn figure is inadvertently exceeded a new collapsible spacer must be fitted 6 When torque to turn figure intermediate gear bearing pre load is correct stake flange of intermediate nut into recess in intermediate shaft 7 Remove tool LRT 41 005 48 OVERHAUL 16 14 41 7296 13 NOTE Discovery cover plate illustrated 8 Up to serial no 288709E Fit and tighten 2 countersunk screws to secure mainshaft input gear bearing housing 9 Remove 2 bolts used to temporarily secure mainshaft input gear bearing housing 10 From serial no 288709E Remove mainshaft input gear bearing housing then apply Hylosil 2000 sealant to mai
21. 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 2 INTRODUCTION 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 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 DESCRIPTION sints ege aati ts 11 OPERATIONS 2 idad eects 13 OVERHAUL TRANSFER BOX DISMANTLING 2 24 0 000 1 COMPONENT DISMANTLING 7 High low cross shaft 0 7 Frontoutput ho sing cand pd
22. ear remove carrier Suitably identify front sun gear to front half of carrier remove sun gear Remove and discard thrust washer Suitably identify each planet gear to its shaft and fitted position of each cross to rear half of carrier Remove retaining ring Remove planet gears and cross shafts remove and discard dished thrust washers Suitably identify rear sun gear to rear half of carrier remove sun gear Remove and discard thrust washer OVERHAUL INSPECTING COMPONENTS 1 Clean all components remove all traces of silicone sealant using suitable solvent and a plastic scraper 2 Up to serial no 288709E Remove all traces of gasket using suitable gasket removal spray and a plastic scraper 3 Clean all traces of Loctite and sealant from threads of bolts and tapped holes Ensure holes are clean and dry CAUTION Do not use a tap to clear threads in tapped holes 4 Check all casings and covers for cracks and damage 5 Replace any component found to be damaged Intermediate gears and shaft 1 Check gear teeth for cracks chipping and uneven wear 2 Check shaft for wear and threads for damage TRANSFER BOX 0 0 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 not have cross drilled shafts If a replacement input gear and shaft is to be fitted the s
23. ent assembling TRANSFER BOX 0 0 Front output housing LRT 51 003 41M7160 I 8 Position propeller shaft flange holding tool LRT 51 003 to output flange 9 Restrain flange tighten nut to 162 Nm 120 lbf ft 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 Ibf ft 6 Fit output flange new felt and steel washers 7 Fita new self locking nut OVERHAUL 43 TRANSFER BOX 10 11 12 13 14 A 44 Compress differential lock selector spring and fit to selector fork Locate fingers of selector fork in groove in dog clutch Fit differential lock selector shaft ensuring end of shaft is located in recess in rear of housing Rotate selector shaft until the two flats for the retaining clips are at right angles to the cover plate mating face Compress selector spring and fit retaining clips at each end of spring CAUTION Ensure ends of spring are fully
24. eve and hub 15 High range gear and bush 16 Differential rear bearing 17 Front output shaft 18 Differential lock selector shaft 19 Selector fork 20 Rear output shaft Mainshaft input gear The gearbox output shaft is splined into the mainshaft input gear which is supported by taper roller bearings Input gear bearing pre load is achieved by the use of a selective shim located in the bearing housing An additional power take off gear is located at the rear of the input gear for certain applications Intermediate gears The intermediate gear cluster is supported by taper roller bearings located at each end of the cluster and running on the intermediate shaft which in turn is supported at the front and rear by the main casing Intermediate gear bearing pre load is achieved by means of a collapsible spacer positioned between the bearings the amount of compression applied to the spacer is by means of a nut on the end of the intermediate shaft DESCRIPTION AND OPERATION 11 TRANSFER BOX 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 shaft carries the low range gear high low selector sleeve and hub high range gear and bush and the differential rear bearing these
25. g track out of housing discard bearing track Remove selective shim OVERHAUL 13 TRANSFER BOX Intermediate gears NO 14 41M7108 Secure intermediate gears in a soft jawed vice Using a soft metal drift drive intermediate shaft bearing track out of gears discard bearing track Remove and discard circlip Repeat above procedure for remaining bearing track OVERHAUL Mainshaft input gear assembly Secure hand press LRT 99 002 a Assemble collars LRT 41 003 around bearing LRT 99 002 41M7109 NOTE Defender input gear illustrated to be removed Position mainshaft in hand press remove and discard bearing Repeat above procedure for remaining bearing TRANSFER BOX 0 0 Differential lock selector Differential 1 Secure differential in a soft jawed vice 2 Remove staking from bearing retaining nut SS Bn 3 Remove nut using tool LRT 41 007 discard nut 41M7110 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 OVERHAUL 15 TRANSFER BOX 41M7112 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 gt SH 41 7113 6 Position differen
26. gh low hub Groove width 7 5 to 7 6 mm 0 295 to 0 30 in 7 Check splines and teeth of high low selector sleeve for uneven wear cracks damage and chipping 8 Check teeth of high and low range gears for cracks chipping and uneven wear 9 Check high range gear bush for wear and damage OVERHAUL 25 TRANSFER BOX 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 gears and dished thrust washers in rear half carrier CAUTION Ensure that cross shafts are in their correct fitted position in rear half carrier Do not fit sun gear into rear half carrier at this stage 5 Fit retaining ring 6 Fit a 1 05 mm 0 04 in thick thrust washer to front half carrier sun gear position gear in front half carrier NOTE This is the thinnest of the thrust washers available 26 OVERHAUL 7 Fit front half carrier to rear ensuring that alignment marks are together 8 Fit bolts and tighten by diagonal selection to 60 Nm 44 Ibf ft 9 Insert front output into front half carrier check that gears rotate freely 10 Fit output flange on to splines of output shaft do not fit flange nut at this stage 11 Fittransmission brake d
27. haft will be cross drilled and it will not be necessary to fit the oil feed plate Defender only 3 Check that ends of dog teeth are not rounded off or chipped OVERHAUL 19 TRANSFER BOX 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 41 7117 3 Check high low selector finger for wear 4 Measure across widest portion of finger Finger width 15 90 to 15 95 mm 0 625 to 0 627 in 20 OVERHAUL Front output housing and differential lock selector 1 Check bearing track recesses in housing for damage rectify or replace housing as necessary 2 Check differential lock selector finger shaft and drilling in housing for wear 527 3 X 41M7118 3 Check differential lock selector finger for wear 4 Measure across widest portion of finger Finger width 15 90 to 15 95 mm 0 625 to 0 627 in LE 41M7119 5 Check differential lock selector finger groove width in differential lock selector Groove width 16 0 to 16 1 mm 0 63 to 0 64 in 41 7120 Check detent grooves in differential lock selector shaft for wear Check differential lock detent ball for flat spots Check detent spring for distortion Check differential lock selector fork for cracks and wear 10 11 12 13
28. ifferential rear bearing Bearing outer track OO JO Om P AM ch N ch TRANSFER BOX 10 0 Bearing retaining nut Dished thrust washers Planet gears Cross shafts Sun gears Selective thrust washers Differential carrier front half Bolt differential carriers Differential front bearing Bearing outer track Selective shim DESCRIPTION AND OPERATION 5 TRANSFER BOX 41M7294B 6 DESCRIPTION AND OPERATION MAIN CASING COMPONENTS P OM ch Main casing Retaining plate Bolt retaining plate Stake nut intermediate shaft Bearings and outer tracks mainshaft input gear Mainshaft input gear Selective shim Gasket Mainshaft input gear bearing housing Oil feed plate O ring Gasket Cover plate power take off cover Bolt cover plate Countersunk screw bearing housing Oil temperature switch Neutral warning lamp switch and washer not kkk Range Rover Classic Defender mainshaft input gear and Discovery power take off cover plate illustrated Up to serial no 288709E fitted TRANSFER BOX 0 0 Bearings and outer tracks intermediate gears Circlips Collapsible spacer Intermediate gears Gasket Bottom cover plate Bolt bottom cover plate C rings intermediate shaft Intermediate shaft Mainshaft oil seal Locating dowel Detent p
29. in casing and that blade of front output housing dowel is positioned as shown 7 Remove oil temperature switch if fitted remove sealant from threads of switch and main casing 8 Apply Hylomar PL32 sealant to threads fit and tighten switch 9 Check high low detent ball for flat spots 10 Check detent spring for distortion ou OVERHAUL 23 TRANSFER BOX 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 41M7124 1 Check detent grooves in for wear 2 Check high low selector finger groove width in shaft Groove width 16 0 to 16 1 mm 0 63 to 0 64 in 24 OVERHAUL 3 Check high low selector fork for cracks and wear 41M7125 4 Check high low selector fork finger width Finger width 7 37 to 7 47 mm 0 290 to 0 294 in TRANSFER BOX 10 0 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 shafts for wear and damage 5 Check teeth of high low hub for cracks chipping and uneven wear 41M7126 6 Check selector fork groove width in hi
30. ing differential lock selector side cover remove cover Up to serial no 288709E Remove and discard gasket Remove 3 bolts securing differential lock selector housing remove housing and selector as an assembly Remove and discard ring from selector housing Remove plug securing differential lock detent spring and ball Remove detent spring Remove ball using a stick magnet CAUTION Suitably identify plug detent spring and ball to their fitted positions do not interchange with high low selector shaft detent components OVERHAUL 7 8 TRANSFER BOX 41M7086 11 8 Compress differential lock selector fork spring and remove retaining clip from each end of 12 spring 9 10 a S Ka 41M7087 9 Withdraw differential lock selector shaft from front output housing recover spring 10 Remove differential lock selector fork 13 14 OVERHAUL 41M7088 Position propeller shaft flange holding tool LRT 51 003 to output shaft flange Remove and discard self locking nut 41M7089 Remove steel and felt washers discard felt washer Remove output shaft flange together with mud shield NOTE A replacement output flange will be supplied together with new mud shield and output shaft oil seal TRANSFER BOX 0 0 C SN 41M70901 19 Using suitable circlip pliers remove and discard circlip retaining output shaft bearing 15 Using a
31. low cross shaft 0 38 38 TRANSFER BOX 55CM8LIMC 39 Mainshaft input gear bearing pre load 39 Rear ott eeng escitas 40 Differential bearing pre load 41 Front output 43 Intermediate TC 46 Intermediate gear bearing 48 Bee EE 49 High low selector shaft detent AA 50 Interlock Solenoid if fitted 2 0 nnn nana nono nnn nor nn nn narra ann 50 TRANSFER BOX CONTENTS Page Neutral warning lamp switch if fitted not Range Rover 51 Differential lock warning lamp switch 51 52 Transmission brake TRANSFER BOX CONTENTS Page DATA TORQUE 8 TOOLS DATA Aar ne ARE 1 2 6 5 2 SERVICE TOOLS wai M C 3 TRANSFER BOX 10 0 This page is intentionally left blank DESCRIPTION AND OPERATION 1 TRANSFER BOX e 17 i SS 41M7058A 2 DESCRIPTION AND OPERATION FRONT OUTPUT HOUSING COMPONENTS High low cross shaft housing Bolt high low cros
32. lug high low selector Detent spring high low selector Detent ball high low selector Interlock solenoid Cover interlock solenoid Bolt interlock solenoid cover Belleville washer XXX DESCRIPTION AND OPERATION 7 TRANSFER BOX 41M7060A 8 DESCRIPTION AND OPERATION REAR OUTPUT HOUSING AND TRANSMISSION BRAKE COMPONENTS Rear output shaft Gasket Rear output housing Bolt rear output housing Speedometer drive gear Spacer Output shaft bearing Circlip Oil seal Mud shield Output shaft flange washer Steel washer Up to serial no 288709E If fitted TRANSFER BOX Gel Self locking nut Transmission brake backplate Bolt transmission brake backplate Transmission brake drum Countersunk screw Speedometer driven gear C ring Speedometer driven gear housing Seal O ring Vehicle speed sensor Allen screw DESCRIPTION AND OPERATION 9 TRANSFER BOX E 41M7347B 6 10 DESCRIPTION AND OPERATION TRANSFER BOX CROSS SECTION Main casing Front output housing Rear output housing Dog clutch Transmission brake Mainshaft input gear Selective shim input gear bearing pre load In
33. n casing mating face of bearing housing position housing on main casing ensuring that reference marks are aligned Fit and tighten 2 countersunk screws if fitted If fitted 11 Lubricate a new ring with recommended oil and fit to oil feed plate 12 Fit oil feed plate ensuring that word TOP is towards top of main casing and spigots are located in cut outs NOTE If a replacement input gear having a cross drilled shaft is to be fitted discard oil feed plate and C ring All transfer boxes 13 14 15 16 A 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 Position clip to stud nut Apply Loctite 290 to threads of bolts and stud nut Fit 5 bolts and stud nut and tighten by diagonal selection to 25 Nm 18 lbf ft NOTE These bolts are threaded to head TRANSFER BOX 0 0 Bottom cover 1 2 Up to serial no 288709E Position new bottom cover gasket dry on main casing From serial no 288709E Apply Hylosil RTV 102 sealant to mating face of bottom cover II Z Fit bottom cover Apply Loctite 290 to threads of bottom cover securing bolts Fit bolts in positions shown and tighten by diagonal selection to 25 Nm 18 lbf ft OVERHAUL 49 TRANSFER BOX High low selector shaft detent RON 50
34. nal selection to 25 Nm 18 Ibf ft Fit output flange new felt and steel washers to output shaft Fita new self locking nut OVERHAUL 10 11 12 13 LRT 51 003 Position propeller shaft flange holding tool LRT 51 003 to output flange Restrain flange tighten nut to 162 Nm 120 41M7168 Lubricate a new ring with recommended oil and fit to vehicle speed sensor if fitted Fit vehicle speed sensor if fitted Fit and tighten Allen screw Differential bearing pre load 41M7270 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 LRT 99 006 PS 014 4 CID 3 Position new differential front bearing outer track on bearing ensuring that track is seated squarely 4 Position setting block tool LRT 41 014 3 on main casing 5 Screw pillar LRT 41 014 4 into tapped hole in main casing 6 Assemble DTI LRT 99 006 to pillar 7 Position stylus of DTI to setting block zero gauge TRANSFER BOX 0 0 ES 41 7359 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 Ensu
35. nd discard gasket 41M7074A 26 26 From serial no 288709E Remove mainshaft input gear bearing housing 41M7348 CAUTION Do not remove mainshaft input AN gear bearing track at this stage 23 Remove oil feed plate if fitted remove and discard ring OVERHAUL 3 TRANSFER BOX 41M7075A 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 0 7 41 7076 EN 28 28 Remove and discard mainshaft oil seal from main casing CAUTION Do not remove mainshaft input gear bearing track at this stage 4 OVERHAUL 29 30 31 41M7077A Remove 6 bolts securing high low cross shaft housing Remove cross shaft housing Up to serial no 288709E Remove and discard gasket CAUTION Do not carry out further dismantling of cross shaft housing at this stage 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 35 Up to serial no 288709E Remove and discard gasket NOTE Dowel located CAUTION Do not carry out further dismantling of front output housing at this stage TRANSFER BOX lt 2 41M7080A 37 36 36 36 Noting their fitted position remove
36. o the differential rear shaft This is achieved by means of the high low selector fork sleeve and splined hub The differential lock when applied prevents all available power being transmitted to the road wheels offering least resistance and is especially useful for off road conditions When selected the selector fork engages the dog clutch on the differential shaft with a gear on the front output shaft this locks the differential and provides fixed drive thereby transmitting equal power to both output shafts TRANSFER BOX Gel DESCRIPTION AND OPERATION 13 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 SS 41M7065 4 Remove countersunk screw securing transmission brake drum remove drum NOTE 2 screws may be fitted 5 Make suitable alignment marks between transmission brake backplate and rear output housing 6 Remove 4 bolts securing transmission brake backplate remove backplate 10 TRANSFER BOX 10 0 41M7066 Remove Allen screw securing vehicle speed sensor if fitted Remove vehicle speed sensor remove and discard O ring if fitted oo Remove 6 bolts securing bottom cover remove cover Up to serial no 288709E Remove and discard gasket OVERHAUL 1 TRANSFER BOX 11 12 13 14 15 2 2 41M7068 1 Rele
37. ove bolts securing front half carrier 28 Remove front half carrier remove sun gear and thrust washer CAUTION Keep selected thrust washer with sun gear 29 Remove retaining ring 30 Remove planet gears and cross shafts TRANSFER BOX 0 0 35 34 32 ES 31 41 7129 31 Fita 1 05 mm 0 04 in thick thrust washer to rear half carrier sun gear position gear in rear half carrier 32 Fit planet gears cross shafts and dished thrust washers in rear half carrier CAUTION Ensure that planet gears are fitted to their respective cross shafts and cross shafts are fitted in their correct location in half carrier 33 Fit retaining ring 34 Fit front half carrier to rear ensuring that alignment marks are together CAUTION Do not fit sun gear and thrust washer into front half carrier 35 Fit bolts and tighten by diagonal selection to 60 Nm 44 lbf ft OVERHAUL 27 TRANSFER BOX 39 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 45 Secure rear half carrier in a soft jawed vice 38 Fit transmission brake drum to output flange 46 Fita new front bearing using tool LRT 41 008 secure with 2 nuts 39 Carry out load to turn check using same method as for front half carrier 40 When load to turn figure is co
38. re that bearing outer track is not disturbed when carrying out above operations 10 Establish average of the 2 readings record figure obtained 41 TRANSFER BOX 13 14 15 16 17 18 19 20 42 41 M73644 Position front output housing as shown Up to serial no 288709E Position a new gasket dry on front output housing Position depth block tool LRT 41 014 2 and cross bar tool LRT 41 014 1 on front output housing Position DTI LRT 99 006 on cross bar LRT 41 014 1 Zero DTI on depth block LRT 41 014 2 Position DTI to cross bar LRT 41 014 1 record reading obtained Remove tools Up to serial no 288709E Remove and retain gasket Using the formula 3 05 mm 0 120 in B A 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 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 OVERHAUL 21 22 23 Retain selected shim and differential front bearing outer track with front output housing Up to serial no 288709E Retain gasket with front output housing Carry out assembly of front output housing See Compon
39. rrect record final figure 41 Upon completion fit sun gear and selected thrust washer to front half carrier 42 Fit front half carrier ensuring that alignment marks are together 43 Fit bolts and tighten by diagonal selection to 60 Nm 44 Ibf ft 44 With differential assembled fit rear output shaft and brake drum and check overall load to turn This should be approximately equal to total load to turn figure of both front and rear half carriers added together Used gears 0 90 kg 2 0 Ib New gears 3 44 kg 7 6 lb 41M7131 28 OVERHAUL 47 48 41M7132 Support front half carrier in a soft jawed vice Fit low range gear ensuring that dog teeth on gear are towards threaded end of shaft NOTE Use a suitable hollow mandrel to fit A gear if it is tight on splines 49 50 51 52 Fit high low hub ensuring that alignment mark made during dismantling is towards threaded end of Fit high low selector sleeve ensuring that alignment marks on hub and sleeve are together Fit bush to high range gear ensuring that collar on bush is on opposite side of gear to the dog teeth Fit high range gear and bush ensuring that collar on bush is towards threaded end of TRANSFER BOX 10 0 XA 41M7133 53 Fita new rear bearing using tool LRT 41 008 LRT 41 007 41M7134 54 Fita new bearing retainer nut tighten to 72 Nm 53 Ibf ft using tool LRT 41 007 CAUTION Do not
40. rum to output flange secure drum using 2 nuts 12 Secure a length of cord around brake drum attach one end of cord to a spring balance 13 Tension cord and note load to turn figure recorded on spring balance when brake drum rotates NOTE Used gears should rotate smoothly whilst new gears will have a notchy feel as they rotate 14 Check figure obtained against specified load to turn figure Used gears 0 45 kg 1 0 lb New gears 1 72 kg 3 8 Ib 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 Selecta thicker thrust washer from the range available NOTE 5 thicknesses of thrust washers are available rising in increments of 0 10 mm 0 004 in from 1 05 to 1 45 mm 0 04 to 0 06 21 Position selected thrust washer and sun gear in front half carrier 22 Fit front half carrier to rear ensuring that alignment marks are together 23 Fit bolts and tighten by diagonal selection to 60 Nm 44 Ibf ft 24 Fit front output shaft and brake drum and repeat load to turn check 25 Repeat above procedures as necessary until load to turn figure is as specified record final figure obtained 26 Remove brake drum from front output shaft remove output shaft 27 Rem
41. s shaft housing O ring High low cross shaft and lever Dog clutch Front output shaft Hollow plug Detent plug differential lock Detent spring differential lock 10 Detent ball differential lock 11 Differential lock warning lamp switch 12 Locknut 13 Front output housing 14 Spring and clips differential lock 15 Differential lock selector fork 16 Side cover 17 Bolt side cover 18 Bolt front output housing 19 High low selector finger 20 Differential lock selector 21 Plug Up to serial no 288709E TRANSFER BOX 0 0 Bearing spacer Output shaft bearing Circlip Oil seal Output shaft flange and mud shield Felt washer Steel washer Self locking nut Differential lock selector finger and shaft OT rings Differential lock selector housing Bolt housing Selector lever Washer Self locking nut Neutral warning lamp switch Range Rover Classic if fitted Gasket high low cross shaft housing Gasket front output housing Gasket side cover plate DESCRIPTION AND OPERATION 3 TRANSFER BOX 41M7292A 4 DESCRIPTION AND OPERATION DIFFERENTIAL COMPONENTS Retaining ring Differential carrier rear half Low range gear High low hub High low selector sleeve High low selector shaft High low selector fork Setscrew high low selector fork High range gear High range gear bush D
42. selector finger passes through the housing locating in a slot in the differential lock selector shaft The differential lock selector shaft passes through the selector fork which is located beneath a plate bolted to the side of the output housing A spring loaded detent ball fitted in the output housing locates in grooves in the shaft A differential lock warning lamp switch operated by movement of the selector fork and shaft is screwed into the top of the output housing Range Rover Classic only For certain markets a neutral warning lamp switch operated by the high low cross shaft is screwed into the side of the housing Rear output housing assembly The rear output shaft is supported in the rear output housing by a single bearing and is splined into the differential rear shaft The output shaft also carries the speedometer drive gear which meshes with the driven gear located in the rear output housing Lubrication Lubrication is by splash oil filler level and drain plugs being located in the main casing An oil temperature switch is also fitted for certain applications 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 by locking either the high or low range gears t
43. shoulder bolt 5 bolts and 2 washers securing rear output housing to main casing 37 Remove rear output housing i NOTE Dowel located 38 Up to serial no 288709E Remove and discard gasket CAUTION Do not carry out further dismantling of rear output housing at this stage OVERHAUL TRANSFER BOX 39 40 41 E lt mel O 9 41 7081 Remove plug securing high low selector shaft detent spring and ball Remove detent spring 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 detent components If fitted 42 43 44 6 Remove 4 bolts securing interlock solenoid cover remove cover and Belleville washer Remove interlock solenoid Remove neutral lamp warning switch and washer OVERHAUL All transfer boxes 41M7082A 45 Withdraw differential assembly together with high low selector shaft and fork TRANSFER BOX 10 0 COMPONENT DISMANTLING en Front output housing High low cross shaft housing 41M7084 Slacken locknut and remove neutral warning lamp switch Range Rover Classic only if fitted Remove setscrew securing high low selector finger to cross shaft Withdraw cross shaft from housing recover high low selector finger Remove and discard O ring 4 2 1 41 7085 G Remove 7 bolts secur
44. termediate gear cluster Intermediate shaft Collapsible spacer SOON OO P GO ch DESCRIPTION Introduction The LT230T transfer box is mounted at the rear of the main gearbox and transmits drive to the front and rear axles via the propeller shafts Construction The transfer box comprises three main assemblies the main casing front output housing and rear output housing The main casing carries the mainshaft input gear the intermediate gears and the differential together with the high low range gears selector shaft and fork The front output housing carries the front output shaft and flange high low cross shaft housing and selector and the differential lock selector shaft and fork A dog clutch on the front output is operated by the differential lock selector fork to engage disengage the differential lock The rear output housing carries the rear output shaft and flange and the speedometer drive and driven gears A mechanically operated transmission brake is attached to the housing the brake drum being attached to the output flange All housings and cover plates are sealed to the the main casing by gaskets or sealant mud and water ingress being prevented by mud shields and throwers located at each end of the output housings and on the drive flanges TRANSFER BOX 0 0 11 Differential assembly 12 Selective shim differential bearing pre load 13 Low range gear 14 High low selector sle
45. tial in hand press with thrust button part of tool LRT 41 001 between press mandrel and differential shaft 7 Press differential out of bearing 9 Remove high range gear and bush taking care not to disturb high low selector sleeve CAUTION Take care that differential does 10 Make suitable alignment marks between A not drop out of bearing high low selector sleeve and hub 11 Remove high low selector sleeve 8 Remove differential from press discard bearing 16 OVERHAUL TRANSFER BOX 0 0 LRT 41 001 16 41M7114 41M7115 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 A end of differential 15 Position differential in hand press with thrust button part of tool LRT 41 001 between press mandrel and differential shaft 16 Press differential out of bearing CAUTION Take care that differential does not drop out of bearing 17 Remove differential from press discard bearing OVERHAUL 17 TRANSFER BOX 18 19 20 21 22 23 24 25 26 27 18 Secure rear half of differential carrier in a soft jawed vice Make suitable alignment marks between front and rear halves of differential carrier Remove 8 bolts securing front half of carrier to r
46. ve 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 1 increments of 0 05 mm 0 002 12 Fit selected shim and using a suitable mandrel 41M7350 24 y fit input gear bearing track 13 Fit mainshaft input gear bearing housing and temporarily secure using 2 M10 x 25 mm bolts 1 Position mainshaft input gear assembly in main tightened to 25 Nm 18 Ibf ft 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 OVERHAUL 39 TRANSFER BOX Rear output housing 1 2 3 A Apply Loctite 290 to threads of bolts and 40 Up to serial no 288709E Position a new gasket dry on main casing From serial no 288709E Apply Hylosil RTV 102 sealant to mating flange of rear output housing 41M7166A Fit rear output housing to main casing NOTE Dowel located shoulder bolt Fit washers to 2 bolts Fit bolts and tighten by diago
47. witch Range Rover Classic only if fitted Fit switch do not tighten locknut until switch has been adjusted NOTE Switch must be adjusted after transfer box 15 installed in vehicle OVERHAUL al 1 3 41M7155 1 Lubricate new O rings with recommended oil fitto 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 Ibf ft TRANSFER BOX 0 0 TRANSFER BOX ASSEMBLING 7 Calculate thickness of shim required using the formula A D where 1 Lubricate all components with recommended A Thickness of installed shim 3 15 mm oil 0 12 in B Recorded end float CAUTION Where use of gaskets 15 C Required pre load 0 05 mm 0 002 in A specified gaskets must be fitted do not D Thickness of shim required use sealant 8 If an alternative shim is required to establish correct end float proceed as follows Mainshaft input gear bearing pre load 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 remo

Land Rover lt230t User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents