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.