Overhaul Manual
LT230T
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LT230T
TRANSFER GEARBOX
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
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Publication title ...................................................................................................................................................
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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
1997 Rover Group Limited
INTRODUCTION
CONTENTS
Page
INFORMATION
INTRODUCTION 1......................................................................................................
REPAIRS AND REPLACEMENTS 2...........................................................................
SPECIFICATION 2......................................................................................................
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,
consult the Repair Manual for the model concerned.
This manual is divided into 3 sections:
Description and Operation,
Overhaul and
Data, Torque & Tools.
To assist filing of revised information, each
sub-section is numbered from page 1.
Individual items are to be overhauled in the
sequence in which they appear in this Manual. Items
numbered in the illustrations are referred to in the
text.
Overhaul operations include reference to Service
Tool numbers and the associated illustration depicts
the tool. Where usage is not obvious the tool is
shown in use. Operations also include reference to
wear limits, relevant data, torque figures, specialist
information and useful assembly details.
WARNINGS, CAUTIONS and Notes have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
References
Operations covered in this manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.
INTRODUCTION
2
INTRODUCTION
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features and corrosion prevention treatments
embodied in the car may be impaired if other than
Land Rover recommended parts are fitted. In certain
territories, legislation prohibits the fitting of parts not
to the manufacturer’s specification.
Torque wrench setting figures given in this Manual
must be used. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is
impaired during removal it must be renewed.
The terms of the vehicle Warranty may be
invalidated by the fitting of other than Land Rover
recommended parts. All Land Rover recommended
parts have the full backing of the vehicle Warranty.
Land Rover Dealers are obliged to supply only Land
Rover recommended parts.
SPECIFICATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
component or vehicle.
This Manual does not constitute an offer for sale of
any particular component or vehicle. Land Rover
Dealers are not agents of the Company and have no
authority to bind the manufacturer by any expressed
or implied undertaking or representation.
TRANSFER BOX
CONTENTS
Page
DESCRIPTION AND OPERATION
FRONT OUTPUT HOUSING COMPONENTS 3.........................................................
DIFFERENTIAL COMPONENTS 5..............................................................................
MAIN CASING COMPONENTS 7...............................................................................
REAR OUTPUT HOUSING AND TRANSMISSION BRAKE COMPONENTS 9..........
DESCRIPTION 11.......................................................................................................
OPERATION 13...........................................................................................................
OVERHAUL
TRANSFER BOX DISMANTLING 1............................................................................
COMPONENT DISMANTLING 7.................................................................................
High/low cross shaft housing 7....................................................................................
Front output housing 7.................................................................................................
Rear output housing 10................................................................................................
Main casing 13.............................................................................................................
Mainshaft input gear bearing housing 13.....................................................................
Intermediate gears 14..................................................................................................
Mainshaft input gear assembly 14...............................................................................
Differential lock selector 15..........................................................................................
Differential 15...............................................................................................................
INSPECTING COMPONENTS 18...............................................................................
Intermediate gears and shaft 19..................................................................................
Mainshaft input gear 19...............................................................................................
High/low cross shaft and housing 20...........................................................................
Front output housing and differential lock selector 20..................................................
Rear output housing 22................................................................................................
Main casing 23.............................................................................................................
Mainshaft input gear bearing housing 23.....................................................................
High/low selector fork and shaft 24..............................................................................
Differential 25...............................................................................................................
COMPONENT ASSEMBLING 26................................................................................
Differential 26...............................................................................................................
Main casing 31.............................................................................................................
Mainshaft input gear bearing housing 32.....................................................................
Mainshaft input gear assembly 33...............................................................................
Intermediate gears 33..................................................................................................
Rear output housing 34................................................................................................
Front output housing 36...............................................................................................
High/low cross shaft housing 38..................................................................................
Differential lock selector 38..........................................................................................
TRANSFER BOX ASSEMBLING 39............................................................................
Mainshaft input gear bearing pre-load 39....................................................................
Rear output housing 40................................................................................................
Differential bearing pre-load 41....................................................................................
Front output housing 43...............................................................................................
Intermediate gears 46..................................................................................................
Intermediate gear bearing pre-load 48.........................................................................
Bottom cover 49...........................................................................................................
High/low selector shaft detent 50.................................................................................
Interlock solenoid - if fitted 50......................................................................................
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.................................................................................................
TRANSFER BOX
CONTENTS
Page
DATA, TORQUE & TOOLS
DATA 1........................................................................................................................
TORQUE FIGURES 2..................................................................................................
SERVICE TOOLS 3.....................................................................................................
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DESCRIPTION AND OPERATION 1
This page is intentionally left blank
TRANSFER BOX
2
DESCRIPTION AND OPERATION
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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 lock
11. Differentiallock warning lamp switch
12. Locknut
13. Front output housing
14. Spring and clips - differential lock
15. Differentiallock selector fork
16. Side cover
17. Bolt - side cover
18. Bolt - front output housing
19. High/low selector finger
20. Differentiallock selector shaft
21. Plug
22. Bearing spacer
23. Output shaft bearing
24. Circlip
25. Oil seal
26. Output shaft flange and mud shield
27. Felt washer
28. Steel washer
29. Self-locking nut
30. Differentiallock selector finger and shaft
31. ’O’ rings
32. Differentiallock selector housing
33. Bolt - housing
34. Selector lever
35. Washer
36. Self-locking nut
37. Neutral warning lamp switch - Range Rover
Classic - if fitted
38. Gasket - high/low cross shaft housing *
39. Gasket - front output housing *
40. Gasket - side cover plate *
* Up to serial no. 288709E
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4
DESCRIPTION AND OPERATION
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DESCRIPTION AND OPERATION 5
DIFFERENTIAL COMPONENTS
1. Retaining ring
2. Differentialcarrier - 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. Differentialrear bearing
12. Bearing outer track
13. Bearing retaining nut
14. Dished thrust washers
15. Planet gears
16. Cross shafts
17. Sun gears
18. Selective thrust washers
19. Differentialcarrier - front half
20. Bolt - differential carriers
21. Differentialfront bearing
22. Bearing outer track
23. Selective shim
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6
DESCRIPTION AND OPERATION
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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 ***
12. Gasket **
13. Cover plate/power take-offcover *
14. Bolt - cover plate
15. Countersunk screw - bearing housing
16. Oil temperature switch ***
17. Neutral warning lamp switch and washer - not
Range Rover Classic ***
18. Bearings and outer tracks - intermediate gears
19. Circlips
20. Collapsible spacer
21. Intermediategears
22. Gasket **
23. Bottom cover plate
24. Bolt - bottom cover plate
25. ’O’ rings - intermediate shaft
26. Intermediateshaft
27. Mainshaft oil seal
28. Locating dowel
29. Detent plug - high/low selector
30. Detent spring - high/low selector
31. Detent ball - high/low selector
32. Interlock solenoid ***
33. Cover - interlock solenoid ***
34. Bolt - interlock solenoid cover ***
35. Belleville washer ***
* Defender mainshaft input gear and Discovery
power take-off cover plate illustrated
** Up to serial no. 288709E
*** If fitted
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8
DESCRIPTION AND OPERATION
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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-locking nut
15. Transmission brake backplate
16. Bolt - transmission brake backplate
17. Transmission brake drum
18. Countersunk screw
19. Speedometer driven gear
20. ’O’ ring
21. Speedometer driven gear housing
22. Seal
23. ’O’ ring **
24. Vehicle speed sensor **
25. Allen screw **
* Up to serial no. 288709E
** If fitted
TRANSFER BOX
10
DESCRIPTION AND OPERATION
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. Intermediategear cluster
9. Intermediateshaft
10. Collapsible spacer
11. Differentialassembly
12. Selective shim - differential bearing pre-load
13. Low range gear
14. High/low selector sleeve and hub
15. High range gear and bush
16. Differentialrear bearing
17. Front output shaft
18. Differentiallock selector shaft
19. Selector fork
20. Rear output shaft
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 shaft 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.
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.
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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 shaft carries the low range gear,
high/low selector sleeve and hub, high range gear
and bush and the differential rear bearing; these
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.
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 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.