Defender (1993+). Manual — part 56

LT230T

TRANSFER GEARBOX

42. Locate the rear differential bearing on

to

the

46. Clean and check high/low selector fork

hub and press

it

into position using the

assembly for wear and renew

if

necessary.

smaller end

of

tool 18G1424, see instruction

47.

To renew the selector fork remove the set

36.

screw and slide the fork from the shaft.

43. Fit the stake nut and tighten

to

the specified

48. Fit the new selector fork with its boss towards

torque using

tool

18G1423.

the three detent grooves. Align the tapped

44.

Check the end float of the high and low range

hole in the fork boss with the indent in the

gears

0,05

to 0,15

mm (0.002

to 0.005

in).

shaft nearest

to

the detent grooves.

49. Apply Loctite

290

to the set screw threads

and

fit

the set screw and tighten

to

the

specified torque.

NOTE: If the clearances vary from those
specified, the assembly must

be rebuilt

using the relevant new

parts.

45. Peen the stake nut collar by carefully forming

the collar

of

the nut into the

slot

as illustrated.

CAUTION:

A round nose tool must be used

for this operation to avoid splitting the
collar of the nut.

Centre differential rear bearing track

50. Fit the differential rear bearing track

1,00

mm

(0.039

in) below the outer face of casing using

a

suitable

tool

as

shown.

20

REISSUED: FEB 1993

LT230T TRANSFER GEARBOX

Rear output housing

-

refit

1.

Grease output housing gasket and position

on

to the rear face of the transfer box casing.

2.

Fit

output housing and ensure clearance of

100

mm (0.039 in) between housing face and

gasket.

3.

Fit

the six output housing bolts with Loctite

290

on the threads, with washers and tighten,

evenly to the correct torque, which will pull the
rear bearing into position.

3.

Fit selector shaft ball and spring through the
side

of

the transfer box casing.

4.

Apply Loctite 290 to detent plug; fit and-
locate, by screwing gently fully home and then
unscrewing two turns.

Centre differential unit refit

1.

Fit

the selector fork/shaft assembly to the

high/low selector sleeve

on

the differential

assembly, with detent groove

to

the rear

of

the

differential assembly.

2.

Locate the differential assembly complete with

selector fork into the transfer box casing. It
may be necessary to rotate the output shaft to
ease fitment, and engage selector shaft into
its hole.

LT230T

TRANSFER

GEARBOX

Front output housing dismantle and overhaul

6.

Withdraw the selector shaft from the rear of
the output housing.

1.

Unscrew seven retaining bolts and washers

7.

Remove the selector fork and spring through

the side cover aperture.

8. Remove lock - up sleeve from the rear of the

and remove the differential lock selector side

2.

Unscrew three retaining bolts and washers

output housing.

and lift the differential lock finger housing and
actuator assembly

from

the front output

3. Slacken the locknut

and

unscrew

the

4. Remove slector shaft detent plug, spring and

9.

Using flange wrench

18G1205

and socket

wrench, remove the flange nut,

steel

and felt

washers.

NOTE: Ensure that flange bolts are fully
engaged

in the wrench.

5.

Compress the selector fork spring and remove
the two spring retaining caps.

cover and gasket.

housing.

differential lock warning light switch.

ball using a suitable magnet.

LT230T TRANSFER GEARBOX

10. Remove the output flange with oil seal shield.

16.

Drift out centre differential front taper roller

bearing track and shim.

NOTE: These parts need not be separated
unless the flange bolts are to be renewed.

11. Drift output shaft rearwards from housing

using a soft headed mallet.

12.

Slide

off

the collar from the output shaft.

13.

Remove and discard oil seal from output
housing using service tool 18G1271 to avoid

damaging the housing.

14.

Remove circlip with circlip pliers 18G257.

17.

Drift out selector shaft cup plug from housing.

18.

Clean all components ensuring all traces of
'Loctite' are removed from faces and threads.

19.

Examine components for wear or damage and
renew if necessary.

NOTE: Renew oil seal and felt seal and

flange nut.

15.

Invert housing and drift out bearing from
inside the case as shown.

Re-assembling front output housing

20. Press the bearing into the housing: do not use

excessive force.

To

facilitate fitting the

bearing, heat the front output housing
uniformally

to

a temperature that must not

exceed 100°C (212°F).

21.

Using circlip pliers, fit the bearing retaining

clips.