Defender (1993+). Manual — part 55

LT230T

TRANSFER GEARBOX

20. Slide drive gear and spacer on

to

the output

4. Secure hand press MS47 in vice with collars

shaft.

18G47BB

-

1

and using button 18G47BB/3

21. Locate output shaft into the bearing in the

remove the rear taper bearing and collars.

housing and drive

into

position.

22.

Locate speedometer gear (driven) housing

assembly into the output housing and press in
until flush with the housing face.

5. Remove the high range gear and bush, taking

care not to disturb the high/low sleeve.

6.

Mark the relationship

of the high/low sleeve to

the hub and then remove the sleeve.

7.

Using a suitable press behind the low range
gear carefully remove the high/low hub and

low

range gear.

Centre differential unit dismantle and overhaul

1. Secure centre differential unit

to a vice

fitted

with

soft jaws, and release stake nut from

recess.

2. Remove stake nut using tool

18G1423

and

suitable socket wrench and discard stake nut.

3.

Remove the differential unit from the vice.

16

REISSUED:

FEB

1993

LT230T TRANSFER GEARBOX

8.

Substituting collar LST47 - 1 remove front
taper roller bearing from the differential.

9.

Remove hand press from the vice.

10.

Using soft jaws secure the differential unit in

the vice by gripping the hub splines.

16.

Inspect all components for damage or wear,

fit

new components

if

necessary.

17.

Using

soft jaws secure the rear (longest half)

of the differential unit

in

the vice by gripping

the hub splines.

18.

Lubricate and install the cross shafts and
pinion gears with new dished washers

DO

NOT fit the rear bevel gear at this stage.

11.

Remove the eight retaining bolts and lift off
the front part

of the differential unit.

12.

Release the retaining ring and remove front
upper sun gear and thrust washer.

13.

Remove the planet gears and dished washers
along with the cross shafts.

14.

Remove the rear lower sun gear and thrust

washer from the rear part of the differential
unit.

15.

Remove the rear differential unit from the vice

and clean all components.

REISSUED: FEB 1993

17

LT230T

TRANSFER GEARBOX

19.

Lubricate and

fit

the front bevel gear

and

thinnest thrust washer (FRC6956 1.05mm).

20. Fit the front half of the differential casing

ensuring that the

two engraved arrows are

aligned.

21. Fit securing bolts and tighten

to the correct

torque (see section 06 - TORQUE

VALUES).

22. Lubricate and insert the rear output shaft into

the bevel gear and check that the gears are
free

to

rotate.

NOTE: Gears that have been run

will rotate

smoothly and

will require a torque of

0.56

Nm (5 in lb). Equivalent force using a
spring balance: 0.45 Kg (1 Ib).
New

gears will rotate with a "notchy" feel

and will require a torque of not more than
2.26 Nm (20 in Ib). Equivalent force using a
spring balance: 1.72 Kg (3.8 Ib).
Keep all components well lubricated

when

carrying out these adjustments.

24. Change the thrust washer for a thicker one

if

the torque reading is too low. Five thrust
washers are available

in

0.10

mm steps

ranging from

1.05

to 1,45 mm.

25. Dismantle the unit when the front bevel gear

thrust washer is selected.

26. Remove and retain the front bevel and thrust

23. Fit the transmission brake drum to the output

washer combination.

drive flange and check the torque required

to

27. Reassemble the unit with the rear bevel gear

rotate the gears. Tie a length of string around

and thinnest thrust washer

in

position.

the brake drum, attach a spring balance

to the

28. Using soft jaws secure the front (shortest half)

string and carefully tension the string until a

of the differential unit in the vice by gripping

load to turn

is

obtained, Alternatively use a

the hub splines.

torque wrench applied

to

the brake drum

29. Repeat the above procedure

to obtain the

flange nut. Rotate the drum slowly by hand to

correct thrust washer for the rear bevel gear.

overcome initial load when using either
method. Note that the illustration RR2332E
shows checking torque at rear bevel gear.

18

REISSUED:

FEB

1993

LT230T TRANSFER GEARBOX

Re-assembling centre differential

30.

Fit the selected thrust washer and bevel gear

into the rear differential unit.

38. Fit the low range gear, with its dog teeth

uppermost

to

the differential assembly.

39.

Press the high/low hub on

to

the differential

splines.

40. Slide the high/low selector sleeve

on to

the

high/low hub ensuring that the alignment
marks are opposite each other.

41. Fit the bush into

the

high range gear

so that

the flange is fitted on the opposite side of the
gear

to the dog teeth. Slide the bushed gear

on to the differential assembly with the dog
teeth down.

31.

Assemble both pinion assemblies and dished
washers onto their respective shafts and fit
the

rear

differential

unit.

Secure

the

assemblies with the retaining ring.

32. Lubricate all the components.
33. Fit the selected thrust washer and bevel gear

into the front upper differential unit.

34. Align both units as previously described and

secure with the eight bolts

to the specified

torque.

35. Check the overall torque required to turn the

differential. This should be approximately
equal to the resistance

of both bevel gears

added together.

36. Locate the front differential bearing onto the

front, upper differential shaft and press into

position using larger end of

tool 18G1424 as

shown.

37.

Invert the differential unit and secure in the
vice.

NOTE: During the following sequences all
parts should be lubricated as they are
fitted.

RElSSUED:

FEB

1993

19