Defender (1993+). Instruction - page 57

LT230T

TRANSFER GEARBOX

22.

Pre

-

grease and fit a new oil seal (lip side

inwards) using replacer

tool

18G1422,

until

the seal just makes contact with the circlip.

29. Grease and fit new gasket and locate the front

output housing on the transfer box casing.

30. Secure housing with the eight retaining bolts

and washers, the upper middle bolt being
longer than the rest. Do not tighten the bolts
at this stage.

31. Engage high or

low

gear.

32. Check the roiling resistance of the differential

using

a

spring balance and a length

of

string

wound around the exposed splines of the
high/low hub.

23. Carefully charge the lips

of

the seal with clean

grease.

24. Slide collar on to the output shaft, with its

chamfered edge away from the dog teeth.

25. Fit

the output shaft through the bearing and

drift home.

Adjusting front differential bearing pre - load

26. Measure original differential front bearing track

shim.

27. Refit original shim into input housing.
28. Drift differential front bearing track into the

housing.

LT230T TRANSFER

GEARBOX

33. With the correct shim fitted the load to turn

NOTE: Ensure that the flange bolts are

should be 1,36 kg to 4,53 kg

(3

Ib to 10 Ib).

NOTE:

Alternatively, fit the

nut to

the

41.

Repeat the above operation for the rear output

output flange and use a suitable torque
wrench to turn the differential.

The

readings should

be

0.56

to

1.69 Nm

(5

to

15

in

Ib). New bearings will register at the

top end

of the torque range and used

bearings will register at the low end.

NOTE: Shims are available i n 0.001 i n
increments.

fully engaged i n the wrench.

flange.

34. If the reading is in excess of the above

measurements, remove the front output
housing assembly from the transfer box

casing.

35. Using a suitable extractor, withdraw the centre

differential bearing track and change the shim
for one of a suitable thickness.

(A

thinner

shim will reduce the rolling resistance).

36. Fit the new shim and drift the differential

bearing track back into its housing until fully
home.

37. Having obtained the load

to

turn, prop

-

up the

transfer box casing on the bench with the
front face uppermost.

42. Compress the selector shaft spring and fit to

housing retaining bolts and fit the eight bolts

43.

Locate selector fork through front output

and washers into the front output housing and

housing side cover aperture, ensuring that the

secure to transfer box casing.

fork engages in the groove of the lock

-

up

39.

Fit

front output flange, felt washers, steel

sleeve.

washers and flange nut.

44.

Fit selector shaft through the aperture in the

40. Using flange wrench 18G1205 and torque

front

of

the output housing and pass it through

wrench, pull the output shaft up

to

the correct

the selector fork lugs and spring into the rear

position. Check that the oil seal shield does

part of the housing.

not foul the housing.

45. Rotate the selector shaft until the two flats for

the spring retaining caps are at right angles to
the side cover plate face.

38. Apply Loctite 290 to the threads of the

the select fork.

LT230T

TRANSFER GEARBOX

46. Compress the spring between the fork lugs

Differential lock finger housing - dismantle and

and slide the retaining caps on

to

the shaft

overhaul

ensuring the spring is captured with the
'cupped' side of the caps.

1.

Unscrew and discard the 'nyloc' nut and

47.

Apply a suitable sealant to a new seal cup

remove the operating lever and washer.

and drive the cup into position.

2.

Remove the pivot shaft from lock finger
housing.

3.

Remove the

'0'

rings from the pivot shaft and

housing and discard.

4.

Clean all components; examine for wear or
damage and renew if necessary.

Re-assembling

5.

Fit

new ' O ' rings on to pivot shaft and lock

finger housing and lubricate with oil.

6. Locate the pivot shaft in the housing.

7.

Fit the differential lock lever over the pivot
shaft

so

that the lever will face forward to the

bend upwards.

This lever is then

in

the correct operating

position.

8. Retain the lever with a plain washer and new

'nyloc' nut.

48. Fit selector shaft detent ball and spring in the

tapped

hole

on top of the output housing.

49.

Apply Loctite 290

to

detent plug threads.

Screw detent plug gently home and then
unscrew

two

turns.

Continued

LT230T

TRANSFER GEARBOX

9.

Fit the differential

lock

finger housing into its

seating on the front output housing, ensuring
that the selector finger is located in the flat

of

the selector shaft.

10.

Apply Loctite 290 to the bolt threads and
retain the lock finger housing with the three
bolts and washers to the specified torque.

11.

Grease and

fit

the high/low selector housing

gasket on the front output housing.

12.

Fit

high/low cross

-

shaft housing, ensuring

that the selector finger locates in the slot of
the selector shaft, and secure with six bolts

and washers to the specified torque.

High/low

cross - shaft housing overhaul

1. Release the locknut and remove the neutral

warning switch.

2. Remove the selector finger set screw and

withdraw the cross-shaft from the cross-shaft
housing and remove the selector finger.

3. Remove the ' 0 ' ring from the cross-shaft.

4. Drive out selector housing cup plug if

necessary.

5. Clean all the components and check for

damage or wear, replace if necessary.

6. Apply sealant to a new cup plug and fit so

that the cup is just below the chamfer for the
cross - shaft bore.

7. Fit new ‘O’ ring to cross - shaft.
8. Lubricate the shaft and insert into the cross -

shaft housing.

9. Fit selector finger ensuring that it aligns with

the recess in the cross - shaft.

10. Apply Loctite 290 to the grub screw and

secure the selector finger to the cross - shaft
and fully tighten to the specified torque.

Input gear overhaul - dismantle and overhaul

1.

Clean the input gear assembly and examine
for wear

or

damage. Remove the bearings

only

if

they are

to

be renewed.

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