Defender (1993+). Manual — part 59

LT230T

TRANSFER

GEARBOX

Differential lock switch adjustment

Transmission brake drum - re-assemble.

1.

Select differential locked position by moving

1.

Clean brake backplate and oil catcher and

the lock taper towards the right side

of

the

apply sealant to the catcher joint face.

transfer box casing.

2.

Locate brake backplate on the rear output

2.

Apply sealant to the differential

lock

warning

housing with the brake operating lever on the

light switch and fit

to

the top of the front

right side

of

the transfer box casing.

output housing.

3.

Secure the backplate (including the oil

3.

Connect a test lamp circuit to the differential

catcher) with the four special bolts and tighten

lock

switch.

using a hexagonal socket to the specified

4.

Screw in the lock switch until the bulb is

torque.

illuminated.

4.

Clean and fit brake drum and secure with two

5.

Turn

in

the switch another half a turn and

tighten with the locknut against the housing.

6. Disconnect the battery and move

the

differential

lock

lever to the left to disengage

differential lock.

7.

Clean the front output housing side cover.

8.

Grease and fit side cover gasket.

9.

Apply Loctite 290 to bolt threads,

fit

side cover

and secure with seven bolts and washers.

countersunk screws.

LT230T TRANSFER GEARBOX

13. Turn the intermediate shaft to allow fitting

of

20.

Peen the stake nut by carefully forming the

retaining plate.

collar

of

the nut into the intermediate shaft

14. Fit retaining plate and secure with retaining

recess, as illustrated.

bolt and washer.

15. Fit the intermediate gear shaft retaining stake

CAUTION: A round nose

tool must

be

used

nut.

for this operation to avoid splitting the
collar

of

the nut.

Power take -

off

cover - reassemble

21. Clean power take - off cover and gasket face.
22. Fit the two countersunk screws and tighten.
23. Remove the six bolts from the bearing support

plate.

24. Apply sealant to the cover plate gasket and fit

it to the bearing support plate.

25.

Apply Loctite 290 to bolt threads and secure
the power take - off cover with the six bolts
and washers.

Bottom

cover - reassemble

Adjusting intermediate gear torque -

to - turn

26.

Clean bottom cover and gasket face.

27. Apply sealant to cover gasket and fit

to

16. Select neutral.

transfer box casing.

17. Fit service tool LST105 to input gear and

28. Apply Loctite 290 to bolt threads and secure

engage spline.

18. Tie a length of string to a split pin and fit to

the service tool as shown. Attach the spring

balance to the string.

19. To obtain the correct figures and to collapse

the spacer within the intermediate gear
cluster, tighten the intermediate shaft nut until
the load - to - turn has increased by 3,7 kg (7
lb) ± 1,63 kg (± 3 lb) on that noted when
checking input shaft load - to - turn.

the bottom cover with six bolts and washers.

LT230T

TRANSFER GEARBOX

Differential lock switch adjustment

Transmission brake drum - re-assemble.

1.

Select differential locked position by moving

1.

Clean brake backplate and oil catcher and

the lock taper towards the right side of the

apply sealant to the catcher joint face.

transfer box casing.

2.

Locate brake backplate on the rear output

2.

Apply sealant to the differential lock warning

housing with the brake operating lever on the

light switch and fit

to

the top of the front

right side of the transfer

box

casing.

output housing.

3.

Secure the backplate (including the oil

3. Connect

a

test lamp circuit to the differential

catcher) with the four special bolts and tighten

lock switch.

using a hexagonal socket to the specified

4.

Screw in the lock switch until the bulb is

torque.

illuminated.

4.

Clean and fit brake drum and secure with

two

5.

Turn

in

the switch another half a turn and

countersunk screws.

tighten with the locknut against the housing.

6. Disconnect the battery and move the

differential lock lever to the left to disengage
differential lock.

7. Clean the front output housing side cover.
8. Grease and fit side cover gasket.
9. Apply Loctite 290 to bolt threads, fit side cover

and secure with seven bolts and washers.

PROPELLER SHAFTS

OVERHAUL PROPELLER SHAFTS

6.

Remove paint, rust, etc. from the vicinity

of

Dismantle

the universal joint bearing cups and circlips.

NOTE: Before dismantling the propeller shaft

1.

Remove the propeller shaft from the vehicle.

joint, mark the position

of the spider pin

2.

If

a gaiter encloses the sliding member

lubricator relative to the journal yoke ears to

release the two securing clips. Slide the gaiter

ensure that

the

grease nipple

boss

is

along the shaft to expose the sliding member.

re-assembled in the correct running position to

3.

Note the alignment markings on the sliding

reduce the possibility of imbalance.

member and the propeller shaft. See NOTE

following instruction 22.

7.

Remove the circlips, and grease nipple.

4.

Unscrew the dust cap and withdraw the
sliding member.

8.

Tap the yokes to eject the bearing cups.

9.

Withdraw the bearing cups and spider and

discard.

10.

Repeat instructions 5 to

8

at opposite end of

propeller shaft.

11.

Thoroughly clean the yokes and bearing cup
locations.

5.

Clean and examine the splines for wear. Worn
splines or excessive back-lash will necessitate
propeller shaft renewal.