Land Rover lt230t User Manual

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TRANSFER GEARBOX

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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 affected ...........................................................................................................................

Technical information errors:

Other improvements/changes you would like us to consider:

Service manager’s signature ..........................................................................

Date ...................................................................................................................

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 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

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......................................................................................

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CONTENTS

Page

Neutral warning lamp switch - if fitted - not Range Rover Classic 51...........................

Differential lock warning lamp switch - adjust 51.........................................................

Transmission brake 52.................................................................................................

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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

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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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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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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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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

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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.

TRANSFER BOX

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.

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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 by locking either the high or low range gears to 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

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 brake backplate and rear output housing.

6. Remove 4 bolts securing transmission brake backplate, remove backplate.

7. Remove Allen screw securing vehicle speed sensor - if fitted.

8. Remove vehicle speed sensor, remove and discard ’O’ ring - if fitted.

9. Remove 6 bolts securing bottom cover, remove cover.

10.

Up to serial no. 288709E:

Remove and

discard gasket.

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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’ ring from main casing.

16. Wrap a suitable length of wire around

intermediate gears and using assistance, lift gears out of main casing.

17. Remove and discard 2 taper roller bearings from intermediate gears.

18. Remove and discard collapsible spacer from intermediate gears.

CAUTION: Do not remove bearing tracks at this stage.

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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 clip.

21. Remove cover plate/power take-off cover.

22.

Up to serial no. 288709E:

Remove and discard

gasket.

23. Remove oil feed plate - if fitted, remove and discard ’O’ ring.

24. Remove 2 countersunk screws - if fitted securing mainshaft input gear bearing housing.

25.

Up to serial no. 288709E:

Remove mainshaft input gear bearing housing, remove and discard gasket.

CAUTION: Do not remove mainshaft input gear bearing track at this stage.

26.

From serial no. 288709E:

Remove mainshaft input gear bearing housing.

CAUTION: Do not remove mainshaft input gear bearing track at this stage.

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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 6 bolts securing high/low cross shaft

housing.

30. Remove cross shaft housing.

31.

Up to serial no. 288709E:

Remove and

discard gasket.

CAUTION: Do not carry out further dismantling of cross shaft housing at this stage.

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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 not carry out further dismantling of front output housing at this stage.

36. Noting their fitted position, remove shoulder

bolt, 5 bolts and 2 washers securing rear output housing to main casing.

37. Remove rear output housing.

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.

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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 securing interlock solenoid

cover, remove cover and Belleville washer.

43. Remove interlock solenoid.

44. Remove neutral lamp warning switch and

washer.

All transfer boxes

45. Withdraw differentialassembly together with

high/low selector shaft and fork.

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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.

Front output housing

1. Remove 7 bolts securing differential lock

selector side cover, remove cover.

Up to serial no. 288709E:

Remove and

discard gasket.

3. Remove 3 bolts securing differential lock selector housing, remove housing and selector as an assembly.

4. Remove and discard ’O’ ring from selector housing.

5. Remove plug securing differential lock detent spring and ball.

6. Remove detent spring.

7. 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.

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OVERHAUL

8. Compress differentiallock selector fork spring

and remove retaining clip from each end of spring.

9. Withdraw differentiallock selector shaft from front output housing, recover spring.

10. Remove differentiallock selector fork.

11. Position propeller shaft flange holding tool LRT-51-003 to output shaft flange.

12. Remove and discard self-locking nut.

13. Remove steel and felt washers, discard felt

washer.

14. 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.

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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 spacer from output shaft.

18. Taking care not to damage front output housing, remove and discard output shaft oil seal.

19. Using suitable circlip pliers, remove and discard circlip retaining output shaft bearing.

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.

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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 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.

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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 shaft and press mandrel.

10. Press output shaft out of housing.

11. Recover spacer and speedometer drive gear

from output shaft.

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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 bearing.

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.

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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 gear bearing housing

1. Secure mainshaft input gear bearing housing in

a soft-jawed vice.

2. Using a soft metal drift, drive input gear bearing track out of housing; discard bearing track.

3. Remove selective shim.

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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 illustrated.

1. Secure hand press LRT-99-002 in a vice.

2. Assemble collars LRT-41-003 around bearing

to be removed.

3. Position mainshaft in hand press, remove and discard bearing.

4. Repeat above procedure for remaining bearing.

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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. Remove nut using tool LRT-41-007; discard

nut.

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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 bearing.

CAUTION: Take care that differential does not drop out of bearing.

8. Remove differential from press, discard

bearing.

9. Remove high range gear and bush taking care not to disturb high/low selector sleeve.

10. Make suitable alignment marks between high/low selector sleeve and hub.

11. Remove high/low selector sleeve.

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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 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.

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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 discard thrust washer.

23. Suitably identify each planet gear to its shaft

and fitted position of each cross shaft to rear half of carrier.

24. Remove retaining ring.

25. Remove planet gears and cross shafts, remove

and discard dished thrust washers.

26. Suitably identify rear sun gear to rear half of carrier, remove sun gear.

27. Remove and discard thrust washer.

INSPECTING COMPONENTS

1. Clean all components, remove all traces of

silicone sealant using suitable solvent and a plastic scraper.

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.

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 not have cross drilled

shafts. If a replacement input gear and shaft is to be fitted, the shaft 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.

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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 15.95 mm (0.625 to

0.627 in)

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.

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)

5. Check differential lock selector finger groove width in differential lock selector shaft: Groove width = 16.0 to 16.1 mm (0.63 to 0.64 in)

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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 0.313 in)

11. Check differential lock selector fork spring for distortion and clips for wear and damage.

12. Check spring free length: Free length = 84.58 mm (3.33 in)

13. Check dog clutch internal teeth and grooves for wear and damage.

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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 necessary.

2. Check speedometer drive and driven gears for damage and wear.

3. Check splines and threads of output shaft for damage and wear.

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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.

6. Check that locating dowels are fitted 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.

Mainshaft input gear bearing housing

1. Check bearing track recess in housing for

damage, rectify or replace housing as necessary.

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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 = 16.0 to 16.1 mm (0.63 to 0.64 in)

3. Check high/low selector fork for cracks and wear.

4. Check high/low selector fork finger width: Finger width = 7.37 to 7.47 mm (0.290 to 0.294 in)

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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 shafts for wear

and damage.

5. Check teeth of high/low hub for cracks, chipping and uneven wear.

6. Check selector fork groove width in high/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.

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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.

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 lbf.ft).

9. Insert front output shaft 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. Fit transmission brake drum 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 lb)

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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 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 in) .

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 lbf.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. Remove 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.

31. Fit a 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).

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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 method as for front half carrier.

40. When load to turn figure is correct, 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 lbf.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 lb) New gears = 3.44 kg (7.6 lb)

45. Secure rear half carrier in a soft-jawed vice.

46. Fit a new front bearing using tool LRT-41-008.

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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.

50. Fit high/low selector sleeve ensuring that alignment marks on hub and sleeve are together.

51. Fit bush to high range gear ensuring that collar on bush is on opposite side of gear to the dog teeth.

52. Fit high range gear and bush ensuring that collar on bush is towards threaded end of shaft.

53. Fit a new rear bearing using tool LRT-41-008.

54. Fit a new bearing retainer nut, tighten to 72 Nm (53 lbf.ft) using tool LRT-41-007.

CAUTION: Do not stake nut at this stage.

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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 sleeve and hub away from high range gear.

59. 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)

60. If clearance is not as specified, fit new high range gear and high/low hub and re-check.

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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, fit a new mainshaft input gear bearing track.

CAUTION: Ensure bearing tracks are seated squarely in recesses.

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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 thinnest of the shims available.

3. Using a suitable mandrel, fit new mainshaft

input gear bearing track.

CAUTION: Ensure bearing track is seated squarely in recess.

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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 bearing.

6. Repeat above procedure for remaining bearing.

Intermediate gears.

1. Lubricate new bearings and bearing tracks with

recommended oil.

2. Fit new circlips into intermediate gears.

CAUTION: Ensure that circlips are correctly seated.

3. Fit new bearing tracks using tools LRT-41-006 and LRT-99-003.

CAUTION: Ensure bearing tracks are fully seated against circlips.

4. Retain bearings with intermediate gears.

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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-41-012.

NOTE: Use end of tool marked ’REAR’ to fit oil seal.

7. Check that oil seal is just contacting circlip.

8. Slide speedometer drive gear and spacer on to

output shaft.

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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 flange at this stage.

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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.

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 °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

fully seated in groove.

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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.

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.

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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 with

recess in cross shaft.

6. Apply Loctite 290 to threads of setscrew, fit and tighten screw.

7. Apply Hylomar PL32 sealant to threads of neutral warning lamp switch - 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 is installed in vehicle.

Differential lock selector

1. Lubricate new ’O’ rings with recommended oil,

fit to selector finger shaft and housing.

2. Insert selector finger shaft into housing.

3. Fit selector lever ensuring that relative

positions of lever and finger are as shown.

4. Fit washer and new self-locking nut, tighten nut to 15 Nm (11 lbf.ft).

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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.

Up to serial no. 288709E:

Fit a new mainshaft input gear bearing housing gasket, dry on main casing.

All transfer boxes:

Fit mainshaft input gear bearing housing ensuring reference marks are aligned.

4. Fit 2 M10 x 25 mm bolts and tighten to 25 Nm (18 lbf.ft).

5. Position suitable DTI with stylus of gauge contacting end of mainshaft, push mainshaft rearwards and zero gauge.

6. Push mainshaft forwards and note gauge reading.

7. Calculate thickness of shim required using the formula A + B + C = D where: A = Thickness of installed shim - 3.15 mm (0.12 in) B = Recorded end-float C = Required pre-load - 0.05 mm (0.002 in) D = Thickness of shim required

8. If an alternative shim is required to establish correct end-float, proceed as follows:

NOTE: Do not remove mainshaft input gear bearing housing if bearing pre-load is correct.

9. Remove 2 bolts, remove mainshaft input gear

bearing housing.

NOTE: Up to serial no. 288709E, retain gasket on main casing.

10. Using a soft metal drift, carefully drive input

gear bearing track out of bearing housing, remove shim.

CAUTION: If bearing track is damaged during this operation, a new track must be fitted.

11. Select required shim from the range available.

NOTE: Shims are available from 3.15 to

4.00 mm (0.12 to 0.16 in) thickness rising in increments of 0.05 mm (0.002 in).

12. Fit selected shim and using a suitable mandrel,

fit input gear bearing track.

13. Fit mainshaft input gear bearing housing and temporarily secure using 2 M10 x 25 mm bolts tightened to 25 Nm (18 lbf.ft).

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Rear output housing

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.

3. Fit rear output housing to main casing.

NOTE: Dowel located.

4. Apply Loctite 290 to threads of bolts and

shoulder bolt.

5. Fit washers to 2 bolts.

6. Fit bolts and tighten by diagonal selection to 25

Nm (18 lbf.ft).

7. Fit output flange, new felt and steel washers to output shaft.

8. Fit a new self-locking nut.

9. Position propeller shaft flange holding tool LRT-51-003 to output flange.

10. Restrain flange, tighten nut to 162 Nm (120

lbf.ft).

11. Lubricate a new ’O’ ring with recommended oil and fit to vehicle speed sensor - if fitted.

12. Fit vehicle speed sensor - if fitted.

13. Fit and tighten Allen screw.

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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 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.

8. Position stylus of gauge on front bearing outer track, record reading obtained.

9. Position stylus of gauge on opposite side of bearing track, record reading obtained.

CAUTION: Ensure that bearing outer track is not disturbed when carrying out above operations.

10. Establish average of the 2 readings, record

figure obtained.

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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.

16. Position DTI to cross-bar LRT-41-014/1, record

reading obtained.

17. Remove tools.

18.

Up to serial no. 288709E:

Remove and retain

gasket.

19. Using the formula:

3.05 mm (0.120 in) + B - A = D where: B = Height difference recorded between depth block and cross bar A = Average of readings to differential front bearing outer track D = Thickness of shim required to give differential bearing pre-load of 0.05 mm (0.002 in)

20. From resultant figure obtained, select appropriate thickness shim from the range available.

NOTE: Shims are available from 2.00 to

3.25 mm (0.08 to 0.13 in) thickness rising in increments of 0.05 mm (0.002 in).

21. Retain selected shim and differential front

bearing outer track with front output housing.

22.

Up to serial no. 288709E:

Retain gasket with

front output housing.

23. Carry out assembly of front output housing

See Component assembling.

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OVERHAUL 43

Front output housing

Up to serial no. 288709E:

Fit gasket used when determining differential bearing pre-load, dry, to main casing.

From serial no. 288709E:

Apply Hylomar RTV 102 sealant to mating flange of front output housing.

All transfer boxes

3. Fit front output housing ensuring that splines of

output shaft are engaged in differential and that internal splines of dog clutch are engaged with teeth of output shaft.

4. Apply Loctite 290 to threads of bolts, fit bolts noting that longest bolt is inserted through high/low selector finger housing.

5. Tighten bolts by diagonal selection to 25 Nm (18 lbf.ft).

6. Fit output flange, new felt and steel washers.

7. Fit a new self-locking nut.

8. Position propeller shaft flange holding tool LRT-51-003 to output flange.

9. Restrain flange, tighten nut to 162 Nm (120

lbf.ft).

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10. Compress differential lock selector spring and

fit to selector fork.

11. Locate fingers of selector fork in groove in dog clutch.

12. Fit differential lock selector shaft ensuring end of shaft is located in recess in rear of housing.

13. Rotate selector shaft until the two flats for the retaining clips are at right angles to the cover plate mating face.

14. Compress selector spring and fit retaining clips at each end of spring.

CAUTION: Ensure ends of spring are fully seated in recess in clips.

15. Fit differential lock detent ball and spring.

16. Apply Loctite 290 to threads of detent plug.

17. Fit and tighten detent plug then unscrew 2 full

turns.

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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 differential lock selector lever and

check that differential lock detent ball can be felt to positively engage and disengage with grooves in selector shaft; screw detent plug in or out until setting is correct.

23. 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.

Up to serial no. 288709E:

Apply grease to new high/low selector housing gasket, position gasket on front output housing.

25.

From serial no. 288709E:

Apply Hylosil RTV 102 sealant to mating flange of high/low selector housing.

26. Fit housing ensuring that high/low selector finger is located in recess in high/low selector shaft.

27. Fit 6 bolts and tighten to 25 Nm (18 lbf.ft).

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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 stage.

3. Lubricate new ’O’ rings with recommended oil

and fit to intermediate shaft and main casing.

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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 intermediate gears.

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-float is

removed. Do not stake nut at this stage.

12. Set intermediate gear bearing pre-load

- See

Intermediate gear bearing pre-load.

TRANSFER BOX

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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 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 lbf.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 shaft nut into recess in intermediate shaft.

7. Remove tool LRT-41-005.

NOTE: Discovery cover plate illustrated.

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 main 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 ’O’ 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 ’O’ ring.

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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 stud nut and tighten by diagonal selection to 25 Nm (18 lbf.ft).

NOTE: These bolts are threaded to head.

Bottom cover

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.

3. Fit bottom cover.

4. Apply Loctite 290 to threads of bottom cover

securing bolts.

5. Fit bolts in positions shown and tighten by diagonal selection to 25 Nm (18 lbf.ft).

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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 until setting is correct.

Interlock solenoid - if fitted

1. Position interlock solenoid in main casing.

2. Apply Hylosil RTV 102 to mating face of

solenoid cover.

3. Fit solenoid cover and Belleville washer, fit bolts and tighten to 10 Nm (8 lbf.ft).

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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 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.

Up to serial no. 288709E:

Apply grease to a new gasket and fit to differential lock side cover.

From serial no. 288709E:

Apply Hylosil RTV 102 sealant to mating face of differential lock side cover.

8. Fit side cover, fit bolts and tighten to 25 Nm (18 lbf.ft).

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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 boxes - 2 screws are fitted.

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.............. 0.295 to 0.30 in

Differential lock selector finger width 15.90 to 15.95 mm............. 0.625 to 0.627 in

Differential lock selector shaft groove width 16.0 to 16.1 mm....... 0.63 to 0.64 in

Differential lock selector fork finger width 7.92 to 7.9......... 0.311 to 0.313 in

Differential lock selector spring free length 84.58 mm........ 3.33 in

Dog clutch selector fork groove width 8.05 to 8.20 mm............ 0.32 to 0.33 in

Differential front and rear half carrier gears load to turn :

Used gears 0.45 kg............................... 1.0lb

New gears 1.72 kg................................ 3.8lb

Thrust washer thicknesses available 1.05 to 1.45 mm............. 0.04 to 0.06 in

In increments of: 0.10 mm........................... 0.004 in

Total load to turn - both sun gears fitted:

Used gears 0.90 kg............................... 2.0lb

New gears 3.44 kg................................ 7.6lb

Low range gear to high range hub clearance 0.05 to 0.15 mm...... 0.002 to 0.006 in

High range gear to high/low hub clearance 0.05 to 0.15 m........ 0.002 to 0.006 in

Mainshaft input gear bearing pre-load 0.05 mm............ 0.002 in

Mainshaft input gear bearing shim thicknesses

available 3.15 to 4.00 mm.................................. 0.12 to 0.16 in

In increments of: 0.05 mm........................... 0.002 in

Differential bearing pre-load 0.05 mm................... 0.002 in

Differential shim thicknesses available 2.00 to 3.25 mm........... 0.08 to 0.13 in

In increments of 0.05 mm............................ 0.002 in

Intermediate gear bearing pre-load An increase on mainshaft input gear

initial torque to turn of 1.25 Nm........................ 10lbf.in

TRANSFER BOX

DATA, TORQUE & TOOLS

TORQUE FIGURES

Drain plug 30 Nm................................. 22lbf.ft

Differential carrier bolts 60 Nm....................... 44lbf.ft

Differential bearing nut 72 Nm....................... 53lbf.ft

Differential lock selector lever nut 15 Nm............... 11lbf.ft

* Front and rear output housing bolts 25 Nm............ 18lbf.ft

Output flange nuts 162 Nm........................... 120lbf.ft

* Differential lock selector housing bolts 25 Nm.......... 18lbf.ft

High/low selector housing bolts 25 Nm................. 18lbf.ft

* Intermediate shaft retaining plate bolt 25 Nm........... 18lbf.ft

* Bottom cover bolts 25 Nm......................... 18lbf.ft

* Bearing housing cover plate bolts and stud nut 25 Nm. . . 18 lbf.ft

Transmission brake backplate bolts 70 Nm............. 52lbf.ft

Interlock solenoid cover bolts - if fitted 10 Nm............ 8lbf.ft

* Apply Loctite 290 to threads

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 Input gear mandrel LRT-41-006 Intermediate gear bearing track replacer LRT-41-007 Differential bearing nut remover/replacer LRT-41-008 Differential bearing replacer LRT-41-011 Output shaft bearing replacer LRT-41-012 Output shaft oil seal replacer LRT-41-014/1 Cross-bar LRT-41-014/2 Depth block LRT-41-014/3 Setting block LRT-41-014/4 Pillar LRT-51-003 Propeller shaft flange holding tool LRT-51-009 Differential rear bearing track replacer LRT-54-003 Differential front bearing track replacer LRT-99-002 Hand press LRT-99-003 Driver handle LRT-99-006 Dial test indicator (DTI)

Land Rover lt230t User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual