Instruction/ maintenance manual of the product lt230t Land Rover
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Overhaul Manual L T230T V erdeelbak revisieboek L T230T Boîte de transfert Manuel de révision L T230T V erteilergetriebe Überholungsanleitung L T230T Riduttore Manuale di revisione L T230T Caja de .
Dealer Stamp Technical Information Review While every attempt is made to ensure that the technical information we supply is as accurate and up to date as possible, from time to time, errors do occur. There may also be instances where the style or content of our publications do not meet your exact needs.
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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.
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INTRODUCTION CONTENTS Page INFORMATION INTRODUCTION 1 ...................................................................................................... REPAIRS AND REPLACEMENTS 2 ...................................................................
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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.
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.
TRANSFER BOX CONTENTS Page DESCRIPTION AND OPERATION FRONT OUTPUT HOUSING COMPONENTS 3 ......................................................... DIFFERENTIAL COMPONENTS 5 .............................................................................. MAIN CASING COMPONENTS 7 .
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 ......................................................
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TRANSFER BOX DESCRIPTION AND OPERATION 1 This page is intentionally left blank.
TRANSFER BOX 2 DESCRIPTION AND OPERATION.
TRANSFER BOX DESCRIPTION AND OPERATION 3 FRONT OUTPUT HOUSING COMPONENTS 1. High/low cross shaft housing 2. Bolt - high/low cross shaft housing 3. ’O’ ring 4. High/low cross shaft and lever 5. Dog clutch 6. Front output shaft 7. Hollow plug 8. Detent plug - differential lock 9.
TRANSFER BOX 4 DESCRIPTION AND OPERATION.
TRANSFER BOX DESCRIPTION AND OPERATION 5 DIFFERENTIAL COMPONENTS 1. Retaining ring 2. Differential carrier - rear half 3. Low range gear 4. High/low hub 5. High/low selector sleeve 6. High/low selector shaft 7. High/low selector fork 8. Setscrew - high/low selector fork 9.
TRANSFER BOX 6 DESCRIPTION AND OPERATION.
TRANSFER BOX DESCRIPTION AND OPERATION 7 MAIN CASING COMPONENTS 1. Main casing 2. Retaining plate 3. Bolt - retaining plate 4. Stake nut - intermediate shaft 5. Bearings and outer tracks - mainshaft input gear 6. Mainshaft input gear * 7. Selective shim 8.
TRANSFER BOX 8 DESCRIPTION AND OPERATION.
TRANSFER BOX DESCRIPTION AND OPERATION 9 REAR OUTPUT HOUSING AND TRANSMISSION BRAKE COMPONENTS 1. Rear output shaft 2. Gasket * 3. Rear output housing 4. Bolt - rear output housing 5. Speedometer drive gear 6. Spacer 7. Output shaft bearing 8. Circlip 9.
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. Intermediate gear cluster 9.
TRANSFER BOX 12 DESCRIPTION AND OPERATION Differential assembly The differential assembly is supported at the front and rear by taper roller bearings, the bearing outer tracks being located in the front and rear output housings. Bearing pre-load is achieved by means of a selective shim located in the front output housing.
TRANSFER BOX DESCRIPTION AND OPERATION 13 OPERATION The gearbox output shaft transmits power to the mainshaft input gear which is in constant mesh with one of the intermediate gears. The intermediate gears are in constant mesh with the high and low range output gears running on the differential rear shaft.
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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.
TRANSFER BOX 2 OVERHAUL 11. Release staking from intermediate shaft nut, remove and discard nut. 12. Remove bolt securing anti-rotation plate, remove plate. 13. Using a soft metal drift on threaded end of intermediate shaft, drive shaft out of main casing.
TRANSFER BOX OVERHAUL 3 NOTE: Discovery cover plate illustrated. 19. Make suitable alignment marks between cover plate/power take-off cover, mainshaft input gear bearing housing and main casing 20.
TRANSFER BOX 4 OVERHAUL 27. Remove mainshaft input gear together with taper roller bearings. NOTE: Input gear fitted to Defender transfer boxes has an additional dog tooth gear - see inset on illustration. 28. Remove and discard mainshaft oil seal from main casing.
TRANSFER BOX OVERHAUL 5 32. Slacken locknut and remove differential lock warning lamp switch from front output housing. 33. Noting fitted position of longest bolt, remove 8 bolts securing front output housing to main casing. 34. Remove front output housing.
TRANSFER BOX 6 OVERHAUL 39. Remove plug securing high/low selector shaft detent spring and ball. 40. Remove detent spring. 41. Remove ball using a stick magnet. CAUTION: Suitably identify plug, detent spring and ball to their fitted positions, do not interchange with differential lock selector shaft detent components.
TRANSFER BOX OVERHAUL 7 COMPONENT DISMANTLING High/low cross shaft housing 1. Slacken locknut and remove neutral warning lamp switch - Range Rover Classic only - if fitted. 2. Remove setscrew securing high/low selector finger to cross shaft. 3. Withdraw cross shaft from housing, recover high/low selector finger.
TRANSFER BOX 8 OVERHAUL 8. Compress differential lock selector fork spring and remove retaining clip from each end of spring. 9. Withdraw differential lock selector shaft from front output housing, recover spring. 10. Remove differential lock selector fork.
TRANSFER BOX OVERHAUL 9 15. Using a mallet, drive output shaft out of front output housing. NOTE: If it is necessary to use a hand press to remove output shaft, position thrust button LRT-370-11/2 between shaft and press mandrel. 16. Noting its fitted position, remove dog clutch from output shaft.
TRANSFER BOX 10 OVERHAUL 22. Invert front output housing. 23. Using a soft metal drift, drive differential bearing track out of housing, discard bearing track. 24. Remove selective shim. Rear output housing 1. Position propeller shaft flange holding tool LRT-51-003 to output shaft flange.
TRANSFER BOX OVERHAUL 11 5. Carefully lever speedometer driven gear and housing out of rear output housing. 6. Remove and discard ’O’ ring. 7. Withdraw speedometer driven gear from housing, remove and discard oil seal from housing. 8. Position rear output housing on bed of hand press.
TRANSFER BOX 12 OVERHAUL 12. Using a screwdriver inserted in slot in rear output housing, lever mud shield out of housing. CAUTION: Discard mud shield if it is damaged. 13. Taking care not to damage rear output housing, remove and discard output shaft oil seal.
TRANSFER BOX OVERHAUL 13 Main casing 1. Support main casing on suitable blocks of wood. 2. Using a soft metal drift, drive differential rear bearing track out of main casing; discard bearing track. 3. Invert main casing. 4. Using a soft metal drift, drive mainshaft input gear bearing track out of main casing; discard bearing track.
TRANSFER BOX 14 OVERHAUL Intermediate gears 1. Secure intermediate gears in a soft-jawed vice. 2. Using a soft metal drift, drive intermediate shaft bearing track out of gears; discard bearing track. 3. Remove and discard circlip. 4. Repeat above procedure for remaining bearing track.
TRANSFER BOX OVERHAUL 15 Differential lock selector 1. Remove and discard self-locking nut retaining selector lever. 2. Remove washer and selector lever. 3. Withdraw selector finger and shaft from housing. 4. Remove and discard ’O’ ring. Differential 1.
TRANSFER BOX 16 OVERHAUL 4. Secure hand press LRT-99-002 in a vice. 5. Secure collars LRT-41-001 around rear bearing. NOTE: This bearing is adjacent to threaded end of differential shaft. 6. Position differential in hand press with thrust button, part of tool LRT-41-001 between press mandrel and differential shaft.
TRANSFER BOX OVERHAUL 17 12. Using a suitable puller and thrust button, part of tool LRT-41-001, remove high/low hub and low range gear. 13. Secure hand press LRT-99-002 in a vice. 14. Assemble collars LRT-41-002 around front bearing. NOTE: This bearing is adjacent to splined end of differential shaft.
TRANSFER BOX 18 OVERHAUL 18. Secure rear half of differential carrier in a soft-jawed vice. 19. Make suitable alignment marks between front and rear halves of differential carrier. 20. Remove 8 bolts securing front half of carrier to rear, remove carrier.
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.
TRANSFER BOX 20 OVERHAUL High/low cross shaft and housing 1. Check mating surfaces of cross shaft and drilling in housing for wear. 2. Check core plug in housing for signs of leakage or corrosion, apply Loctite 326 to replacement plug. 3. Check high/low selector finger for wear.
TRANSFER BOX OVERHAUL 21 6. Check detent grooves in differential lock selector shaft for wear. 7. Check differential lock detent ball for flat spots. 8. Check detent spring for distortion. 9. Check differential lock selector fork for cracks and wear. 10.
TRANSFER BOX 22 OVERHAUL 14. Check dog clutch selector fork groove width: Groove width = 8.05 to 8.20 mm (0.32 to 0.33 in) 15. Check threads and splines of output shaft for damage and wear. 16. Check dog clutch teeth on shaft for wear and damage. Rear output housing 1.
TRANSFER BOX OVERHAUL 23 Main casing 1. Check bearing track recesses in main casing for damage, rectify or replace casing as necessary. 2. Remove drain plug, discard sealing washer. 3. Fit new sealing washer, fit drain plug and tighten to 30 Nm (22 lbf.
TRANSFER BOX 24 OVERHAUL High/low selector fork and shaft NOTE: There is no need to remove selector fork from shaft unless fork or shaft is to be replaced. If fork is removed, coat threads of setscrew with Loctite 290 prior to assembly. 1. Check detent grooves in shaft for wear.
TRANSFER BOX OVERHAUL 25 Differential 1. Check sun and planet gears for wear, cracks and chipping of teeth. 2. Check cross shafts and recesses in both halves of differential carrier for damage and wear. CAUTION: Ensure planet gears are retained with their respective shafts.
TRANSFER BOX 26 OVERHAUL COMPONENT ASSEMBLING 1. Lubricate all components with recommended oil. Differential 1. Lightly oil threads of differential bolts. 2. Secure rear half of differential carrier in a soft-jawed vice. 3. Fit each planet gear to its respective cross-shaft, fit new dished thrust washer to each gear.
TRANSFER BOX OVERHAUL 27 15. If load to turn figure is below that specified, proceed as follows. 16. Remove front output shaft together with brake drum. 17. Remove 8 bolts securing front half differential carrier. 18. Remove front half differential carrier.
TRANSFER BOX 28 OVERHAUL 36. Invert assembly in vice and then insert rear output shaft into rear half carrier, check that gears rotate freely. 37. Fit output flange on to splines of output shaft, do not fit flange nut at this stage. 38. Fit transmission brake drum to output flange, secure with 2 nuts.
TRANSFER BOX OVERHAUL 29 47. Support front half carrier in a soft-jawed vice. 48. Fit low range gear ensuring that dog teeth on gear are towards threaded end of shaft. NOTE: Use a suitable hollow mandrel to fit gear if it is tight on splines. 49. Fit high/low hub ensuring that alignment mark made during dismantling is towards threaded end of shaft.
TRANSFER BOX 30 OVERHAUL 55. Slide high/low selector sleeve and hub away from low range gear. 56. Using feeler gauges, determine clearance between low range gear and high/low hub: Clearance = 0.05 to 0.15 mm (0.002 to 0.006 in) 57. If clearance is not as specified, fit a new low range gear and high/low hub and re-check.
TRANSFER BOX OVERHAUL 31 61. Using a round nosed punch, stake collar of nut into recess in differential shaft. Main casing 1. Fit a new differential rear bearing track using tool LRT-51-009. 2. Using a straight edge and feeler gauges, check that bearing track is recessed 1.
TRANSFER BOX 32 OVERHAUL 4. Lubricate a new mainshaft oil seal with recommended oil. 5. Invert main casing and fit oil seal, lip side facing inwards, using tool LRT-37-014. Mainshaft input gear bearing housing 1. Ensure bearing track recess in housing is clean.
TRANSFER BOX OVERHAUL 33 Mainshaft input gear assembly 1. Lubricate new bearings with recommended oil. 2. Secure hand press LRT-99-002 in a vice. 3. Position collars LRT-41-003 in hand press. 4. Position new bearing on collars. NOTE: Smallest diameter of bearing must be towards collars.
TRANSFER BOX 34 OVERHAUL Rear output housing 1. Heat rear output housing to 100 ° C (210 ° F). 2. Fit new output shaft bearing using tool LRT-41-011. 3. Allow housing to air cool. 4. Fit new bearing retaining circlip ensuring it is seated in groove.
TRANSFER BOX OVERHAUL 35 9. Position rear output housing on bed of hand press. 10. Locate threaded end of output shaft in bearing. 11. Position thrust button LRT-37-11/2 between end of output shaft and press mandrel. 12. Press output shaft into bearing.
TRANSFER BOX 36 OVERHAUL 14. Fit speedometer driven gear into rear output housing ensuring that gear teeth are engaged with drive gear. 15. Lubricate a new ’O’ ring with recommended oil and fit to driven gear housing. 16. Fit driven gear housing. 17.
TRANSFER BOX OVERHAUL 37 5. Lubricate a new output shaft oil seal with recommended oil. 6. Fit oil seal using tool LRT-41-012. NOTE: Use end of tool marked ’FRONT’ to fit oil seal. 7. Check that oil seal is just contacting circlip. 8. Position selected shim in front output housing.
TRANSFER BOX 38 OVERHAUL High/low cross shaft housing 1. Lubricate cross shaft and new ’O’ ring with recommended oil. 2. Insert cross shaft into housing, position high/low selector finger on shaft. 3. Fit ’O’ ring to shaft, locate end of shaft in hollow plug.
TRANSFER BOX OVERHAUL 39 TRANSFER BOX ASSEMBLING 1. Lubricate all components with recommended oil. CAUTION: Where use of gaskets is specified, gaskets must be fitted; do not use sealant. Mainshaft input gear bearing pre-load 1. Position mainshaft input gear assembly in main casing.
TRANSFER BOX 40 OVERHAUL Rear output housing 1. Up to serial no. 288709E: Position a new gasket, dry on main casing. 2. From serial no. 288709E: Apply Hylosil RTV 102 sealant to mating flange of rear output housing. 3. Fit rear output housing to main casing.
TRANSFER BOX OVERHAUL 41 Differential bearing pre-load 1. Position high/low selector shaft and fork to differential ensuring that fingers of selector fork are located in high/low selector sleeve. 2. Position high/low selector shaft and differential in main casing ensuring that splines of rear output shaft are engaged in differential.
TRANSFER BOX 42 OVERHAUL 11. Position front output housing as shown. 12. Up to serial no. 288709E: Position a new gasket, dry, on front output housing. 13. Position depth block, tool LRT-41-014/2 and cross-bar, tool LRT-41-014/1 on front output housing.
TRANSFER BOX OVERHAUL 43 Front output housing 1. Up to serial no. 288709E: Fit gasket used when determining differential bearing pre-load, dry, to main casing. 2. From serial no. 288709E: Apply Hylomar RTV 102 sealant to mating flange of front output housing.
TRANSFER BOX 44 OVERHAUL 10. Compress differential lock selector spring and fit to selector fork. 11. Locate fingers of selector fork in groove in dog clutch. 12. Fit differential lock selector shaft ensuring end of shaft is located in recess in rear of housing.
TRANSFER BOX OVERHAUL 45 18. Ensure ’O’ ring is correctly located on differential lock selector housing. 19. Fit differential lock selector assembly ensuring that selector finger is located in recess in differential lock selector shaft. 20. Apply Loctite 290 to threads of bolts.
TRANSFER BOX 46 OVERHAUL Intermediate gears 1. Insert a new collapsible spacer into intermediate gears, fit bearings into bearing tracks. 2. Wrap a suitable length of wire around intermediate gears and using assistance, lower gears into main casing ensuring that they are meshing with input and differential gears.
TRANSFER BOX OVERHAUL 47 4. Raise intermediate gears until dummy shaft LRT-41-004 can be inserted from front output housing side of main casing. 5. Fit intermediate shaft, drift shaft into position whilst at the same time expelling dummy shaft LRT-41-004 .
TRANSFER BOX 48 OVERHAUL Intermediate gear bearing pre-load 1. Select neutral. 2. Screw a suitable bolt into tapped hole in end of tool LRT-41-005. 3. Insert tool LRT-41-005 in end of mainshaft. 4. Using a suitable torque meter on tool LRT-41-005, check and record torque to turn mainshaft input gears.
TRANSFER BOX OVERHAUL 49 All transfer boxes 13. Apply Hylosil RTV 102 sealant or position new, dry gasket to mating face of cover plate/power take-off cover. Position plate/cover on bearing housing ensuring that reference marks are aligned. 14. Position clip to stud nut.
TRANSFER BOX 50 OVERHAUL High/low selector shaft detent 1. Fit detent ball and spring. 2. Apply Loctite 290 to threads of detent plug. 3. Fit and tighten plug then unscrew 2 full turns.
TRANSFER BOX OVERHAUL 51 Neutral warning lamp switch - if fitted - not Range Rover Classic 1. Apply Hylosil PL32 sealant to threads of switch. 2. Fit washer, fit and tighten switch. Differential lock warning lamp switch - adjust 1. Move differential lock selector fork to differential locked position.
TRANSFER BOX 52 OVERHAUL Transmission brake 1. Apply Hylosil RTV 102 sealant to mating face of rear output housing. 2. Position brake backplate on rear output housing ensuring that alignment marks are together. 3. Fit 4 bolts and tighten to 70 Nm (52 lbf.
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.
TRANSFER BOX 2 DATA, TORQUE & TOOLS TORQUE FIGURES Drain plug 30 Nm ................................. 2 2 lbf.ft Differential carrier bolts 60 Nm ....................... 4 4 lbf.ft Differential bearing nut 72 Nm ....................... 5 3 lbf.ft Differential lock selector lever nut 15 Nm .
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-41-00.
An important point after buying a device Land Rover lt230t (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Land Rover lt230t yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Land Rover lt230t - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Land Rover lt230t you will learn all the available features of the product, as well as information on its operation. The information that you get Land Rover lt230t will certainly help you make a decision on the purchase.
If you already are a holder of Land Rover lt230t, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Land Rover lt230t.
However, one of the most important roles played by the user manual is to help in solving problems with Land Rover lt230t. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Land Rover lt230t along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
