LT230Q TRANSFER BOX. Manual — part 10
TRANSFER BOX
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High/low selector fork and shaft
NOTE: There is no need to remove
selector fork from shaft unless fork or
shaft is to be replaced. If fork is removed,
coat threads of set screw with Loctite 290 prior
to assembly.
1. Check detent grooves in shaft for wear.
2. Check high/low selector finger groove width in
shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64
in)
3. Check high/low selector fork for cracks and
wear.
4. Check high/low selector fork finger width:
Finger width = 7.37 to 7.47 mm (0.290 to 0.294
in)
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Differential
1. Check sun and planet gears for wear, cracks
and chipping of teeth.
2. Check cross shafts and recesses in both
halves of differential carrier for damage and
wear.
CAUTION: Ensure planet gears are
retained with their respective shafts.
3. Check retaining ring for distortion.
4. Check splines of differential for wear and
damage.
5. Check teeth of high/low hub for cracks,
chipping and uneven wear.
6. Check selector fork groove width in high/low
hub:
Groove width = 7.5 to 7.6 mm (0.295 to 0.3 in)
7. Check splines and teeth of high/low selector
sleeve for uneven wear, cracks, damage and
chipping.
8. Check teeth of high and low range gears for
cracks, chipping and uneven wear.
9. Check high range gear bush for wear and
damage.
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COMPONENT ASSEMBLING
1. Lubricate all components with recommended
oil.
Differential
1. Lightly oil threads of differential bolts.
2. Secure rear half of differential carrier in a
soft-jawed vice.
3. Fit each planet gear to its respective
cross-shaft, fit new dished thrust washer to
each gear.
4. Fit cross-shafts, planet gears and dished thrust
washers in rear half carrier.
CAUTION: Ensure that cross-shafts are in
their correct fitted position in rear half
carrier. Do not fit sun gear into rear half
carrier at this stage.
5. Fit retaining ring.
6. Fit a 1.05 mm (0.04 in) thick thrust washer to
front half carrier sun gear, position gear in front
half carrier.
NOTE: This is the thinnest of the thrust
washers available.
7. Fit front half carrier to rear ensuring that
alignment marks are together.
8. Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
9. Insert front output shaft into front half carrier,
check that gears rotate freely.
10. Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
11. Fit transmission brake drum to output flange,
secure drum using 2 nuts.
12. Secure a length of cord around brake drum,
attach one end of cord to a spring balance.
13. Tension cord and note load to turn figure
recorded on spring balance when brake drum
rotates.
NOTE: Used gears should rotate smoothly
whilst new gears will have a ’notchy’ feel
as they rotate.
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14. Check figure obtained against specified load to
turn figure:
Used gears = 0.45 kg (1.0 lb)
New gears = 1.72 kg (3.8 lb)
15. If load to turn figure is below that specified,
proceed as follows.
16. Remove front output shaft together with brake
drum.
17. Remove 8 bolts securing front half differential
carrier.
18. Remove front half differential carrier.
19. Remove front half carrier sun gear and thrust
washer.
20. Select a thicker thrust washer from the range
available.
NOTE: 5 thicknesses of thrust washers are
available rising in increments of 0.10 mm
(0.004 in) from 1.05 to 1.45 mm (0.04 to
0.06 in).
21. Position selected thrust washer and sun gear
in front half carrier.
22. Fit front half carrier to rear ensuring that
alignment marks are together.
23. Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
24. Fit front output shaft and brake drum and
repeat load to turn check.
25. Repeat above procedures as necessary until
load to turn figure is as specified; record final
figure obtained.
26. Remove brake drum from front output shaft,
remove output shaft.
27. Remove bolts securing front half carrier.
28. Remove front half carrier, remove sun gear
and thrust washer.
CAUTION: Keep selected thrust washer
with sun gear.
29. Remove retaining ring.
30. Remove planet gears and cross shafts.
31. Fit a 1.05 mm (0.04 in) thick thrust washer to
rear half carrier sun gear, position gear in rear
half carrier.
32. Fit planet gears, cross shafts and dished thrust
washers in rear half carrier.
CAUTION: Ensure that planet gears are
fitted to their respective cross-shafts and
cross-shafts are fitted in their correct
location in half carrier.
33. Fit retaining ring.
34. Fit front half carrier to rear ensuring that
alignment marks are together.
CAUTION: Do not fit sun gear and thrust
washer into front half carrier.
35. Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
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