Defender (1993+). Manual — part 58

LT230T

TRANSFER GEARBOX

2.

Secure hand press MS47 in the vice and

7. Prop up the transfer box casing on the bench

using collars 18G47 - 7 and button 18G47 -
BB/3, remove rear taper roller bearing from

3. Invert input gear assembly in hand press and

remove front taper roller bearing.

4.

Clean input gear.

with the rear face uppermost.

8. Drift in the front taper bearing track.

input gear assembly.

9.

Reposition transfer box casing

so

the front

face is uppermost and fit

oil

seal (lip side

inwards) using replacer tool 18G1422.

Re-assembling input gear assembly

5.

Position rear taper roller bearing on input gear

and using hand press MS47 and collars

18G47

-

7

press the shaft onto bearing.

6. Invert input gear and fit the front taper roller

bearing using the press and collars.

10. Lubricate both bearings with clean

oil.

11. Fit the input gear assembly into the transfer

box casing with the dog teeth uppermost.

Checking input gear bearing pre - load

19.

Tie a length of string

to

the split pin and

fit it

to

the service tool as shown.

12. Secure bearing support plate in the vice. Drift

20. Attach a spring balance to the string and

out input gear bearing track, and remove

carefully tension the spring until a load to turn

shim.

the

input gear is obtained.

A

pull of 2,26 kg

to

9 kg

(5

Ib

to 20 Ib) is required.

NOTE: Alternatively using a suitable torque
wrench applied to the nut on the service

tool, torque to turn the input gear should

be

0.56 to

2.25

Nm

(5

to

20

in Ib).

21. If the reading obtained is outside the above

limits, the original shim must be changed.

22. Remove the spring balance, string and service

tool.

23. Remove the six bolts and the bearing support

plate.

24.

Drift out the input gear bearing track from the
support plate and discard original

shim.

25.

Select the correct size shim to obtain

a

load

to turn

of

2,26 kg to 9 kg

(5

Ib

to

20

Ib)

or

torque to turn 0.56 to 2.25

Nm

(5

to

20 i n

lb).

26. Fit shim to support plate, locate bearing track

and press home.

27. Fit bearing support plate and secure

to

13.

Clean bearing support plate and shim.

transfer box casing with the six bolts

(do

not

Measure original shim and note its thickness.

tighten).

14.

Fit

the original shim

to

the support plate.

28. Repeat the rolling resistance check as

15.

Locate the bearing track in the support plate

previously described, and note the value

and press fully home.

16.

Apply grease to the gasket and fit on to the
transfer box casing.

17.

box casing and secure with the six bolts, but
do not tighten,

18.

Fit the service tool LST105

to

input gear and

engage the spline.

2.

Remove circlips.

obtained.

Fit the bearing support plate on to the transfer

Intermediate gear assembly overhaul

1.

Drift out intermediate gear bearing tracks.

3.

Clean all intermediate gear components and

Intermediate gear reassembly

7.

Check for damage to the intermediate shaft

4.

Fit new circlips into the intermediate gear

thread and if necessary clean up with a fine

5.

Using tools LST550 - 4 and MS550 fit bearing

8. Lubricate the taper roller bearing and

intermediate gear shaft.

9.

Insert new bearing spacer to gear assembly,

followed by the taper roller bearings.

lock plate. Check for damage or wear and
replace as necessary.

cluster,

file or stone.

tracks into the intermediate gear cluster.

10.

Fit dummy shaft

LST104

into the intermediate

gear cluster.

11.

Locate the gear assembly into the transfer box

casing from the

bottom

cover aperture.

12.

Insert intermediate shaft

from

the front of the

transfer

box

casing, pushing the dummy shaft

right through as shown and remove. (Making
sure that the intermediate gear cluster meshes
with the input gear and high range and low
range gears.)

6. Fit the

‘O’

rings

to

the intermediate shaft and

into the intermediate shaft bore at

the

front of

the transfer

box

casing.

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

Ib) ± 1,63 kg (± 3 Ib) on that noted when
checking input shaft load - to - turn.

the

bottom

cover with

SIX

bolts and washers.