Defender (1993+). Manual — part 52
LT230T
TRANSFER GEARBOX
TRANSFER GEARBOX DATA
Front and rear bevel gear pre-load . . . . . . . . ... see text
High range gear end-float . . . . . . . . . . . . .
0,05 to 0,15 mm (0.002 to 0.006 in)
Front differential bearing pre-load . . . . . . . . .
0.56 to 1.69 Nm (5 to 15 in Ib)
Input gear bearing pre-load . . . . . . . . . . . ..
0.56 to 2.25 Nm (5 to 20 in Ib)
Intermediate shaft bearing pre-load . . . . . . . . .
0.56 to 1.69 Nm (5 to 15 Ib)
REISSUED: FEB
1993
LT230T
TRANSFER
GEARBOX
TORQUE WRENCH SETTING
WARNING: Components in bold type must not be re-used
.
COMPONENT
Nm
ft
Ib
Rear output/speedometer housing
. . . . . . . . . . .
16
to
21'
Front output housing to transfer case
. . . . . . . . .
22
to
28
16
to
21'
Cross shaft housing
to
front output housing
. . . . . . ..
22
to
28
16
to
21
Gear change housing
22 to 28
16
to
21
Pivot shaft
to
link arm
. . . . . . . . . . . . . . . .
22
to
28
16
to
21
Connecting rod
to
adjustable clevis
. . . . . . . . . ...
22
to
28
16
to
21
Anti-rotation plate intermediate shaft
. . . . . . . . . .
22
to
28
16
to
21'
Front output housing cover
. . . . . . . . . . . . .
22 to 28
16
to
21*
Pivot bracket
to
extension housing
. . . . . . . . . .
22
to
28
16
to
21*
Finger housing
to
front output housing
. . . . . . . . ..
22 to 28
16
to
21'
Bearing housing
to
transfer case
. . . . . . . . . . ...
22
to
28
16
to
21
Brake drum
to
coupling flange
. . . . . . . . . . . ...
22
to
28
16 to 21
Bearing housing cover to transfer gearbox
. . . . . . .
40
to 50
29
to
37'
29
to
37'
16
to
21'
16
to
21'
48
to
59
4.82 max
9
to
37
19
to
26
40
to
47
50 to
59
19 to 26
10 to
12
30
to
38
30
to
38
24
to
20
38
13
to
16
See note
. . . . . . . . . . . .
Bottom cover
to
transfer case
22
to
28
. . . . . . . . . . . . . . . .
Rear output speedometer housing
to
Selector finger to cross shaft high/low
40 to 50
22
to
28
transfer gearbox
. . . . . . . . . . . . . . . . ..
. . . . . . . . ...
Selector fork. high/low to shaft
. . . . . . . . . . . ...
22 to 28
Transmission brake
to
speedometer housing
. . . . . .
65
to
80
Plunger switch setting
. . . . . . . . . . . . . . .
6.75 max
Gearbox
to
transfer case
. . . . . . . . . . . . . ...
40
to
50
Gearbox
to
transfer case
. . . . . . . . . . . . . ...
Oil
drain plug
. . . . . . . . . . . . . . . . . . ..
25
to
35
Differential case
(front
to
rear)
. . . . . . . . . . . ...
55
to 64
Differential case rear stake nut
. . . . . . . . . . ...
66
to 80
Oil filler/level plug
25 to
35
Transfer breather
. . . . . . . . . . . . . . . . ...
14
to
16
Transfer box front drive flange
to drive shaft
. . . . . . .
41
to 52
Transfer box rear drive flange
to drive shaft
. . . . . . ..
41
to 52
Mounting brackets to transfer gearbox
. . . . . . . . ..
52
Mounting rubbers
to
mounting brackets
. . . . . . . . .
20
to
22
See note
. . . . . . . . . . . . . . . . . .
Output flanges
146 to 179
108 to 132
. . . . . . . . . . . . . . . . ...
Transfer gearbox mounting brackets to chassis
. . . . .
33
to 27
NOTE: Studs to
be assembled into casting with sufficient torque to wind them fully home, but this
torque must not exceed the maximum figure quoted for the associated nut on final assembly
.
NOTE: * These bolts must have threads coated with Loctite
290
prior to assembly
.
LT230T
TRANSFER GEARBOX
DIFFERENTIAL AND OUTPUT
DRIVE ASSEMBLY
1.
Differential selector assembly
2.
Front output housing
3.
4.
5.
6.
High-low selector finger
7.
Differential
lock
selector shaft
8.
Differential
lock
selector fork
9.
10.
11.
12.
Front output flange
13.
Mud shield
14.
Oil seal
15.
Bearing
16.
Spacer
17.
Circlip
18.
Differential carrier,
front
half
19.
Differential carrier, rear half
20.
Retaining ring
21.
Front output shaft
22.
23.
Selective shim
24.
Bearing
25.
Selective thrust washers
26.
Sun and planet gears
27.
Thrust washers
28.
Cross shafts
31.
High output gear
32.
Bush
33.
Bearing
34.
Bearing retaining nut
35.
Differential
lock
switch
36.
High-low ratio cross shaft assembly
High-low selector shaft and lever
High-low selector fork and shaft
Differential lock spring and clips
Front output housing cover and housing
Felt washer, steel washer and flange nut
Dog clutch, front drive lock-up
30.
Hub and sleeve assembly
Differential
lock detent ball and spring
REISSUED:
FEB
1993
7
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