LT230Q TRANSFER BOX. Manual — part 15
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15. Fit differential lock detent ball and spring.
16. Apply Loctite 290 to threads of detent plug.
17. Fit and tighten detent plug then unscrew 2 full
turns.
18. Ensure ’O’ ring is correctly located on
differential lock selector housing.
19. Fit differential lock selector assembly ensuring
that selector finger is located in recess in
differential lock selector shaft.
20. Apply Loctite 290 to threads of bolts.
21. Fit bolts and tighten to 25 Nm (18 lbf.ft).
22. Operate differential lock selector lever and
check that differential lock detent ball can be
felt to positively engage and disengage with
grooves in selector shaft; screw detent plug in
or out until setting is correct.
23. Apply Hylomar PL32 sealant to threads of
differential lock warning lamp switch, fit switch.
CAUTION: Do not allow sealant to contact
switch plunger. Do not tighten locknut or
fit differential lock side cover until switch
has been adjusted.
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24. Apply Hylosil RTV 102 sealant to mating flange
of high/low selector housing.
25. Fit housing ensuring that high/low selector
finger is located in recess in high/low selector
shaft.
26. Fit 6 bolts and tighten to 25 Nm (18 lbf.ft).
Intermediate gears
1. Insert a new collapsible spacer into
intermediate gears, fit bearings into bearing
tracks.
2. Wrap a suitable length of wire around
intermediate gears and using assistance, lower
gears into main casing ensuring that they are
meshing with input and differential gears.
CAUTION: Do not remove wire at this
stage.
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3. Lubricate new ’O’ rings with recommended oil
and fit to intermediate shaft and main casing.
4. Raise intermediate gears until dummy shaft
LRT-41-004 can be inserted from front output
housing side of main casing.
5. Fit intermediate shaft, drift shaft into position
whilst at the same time expelling dummy shaft
LRT-41-004 .
CAUTION: Ensure ’O’ ring is not displaced
from main casing.
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6. Remove wire from around intermediate gears.
7. Rotate intermediate shaft until retaining plate
can be located on flat on shaft.
8. Apply Loctite 290 to threads of retaining plate
bolt.
9. Fit bolt and tighten to 25 Nm (18 lbf.ft).
10. Fit a new intermediate shaft nut.
11. Tighten intermediate shaft nut in small stages
until all end-float is just removed from
intermediate gears.
CAUTION: Check end-float of intermediate
gears between each stage, do not
continue tightening nut after end-float is
removed. Do not stake nut at this stage.
12. Set intermediate gear bearing pre-load
- See
Intermediate gear bearing pre-load.
Intermediate gear bearing pre-load
1. Select neutral.
2. Screw a suitable bolt into tapped hole in end of
tool LRT-41-005.
3. Insert tool LRT-41-005 in end of mainshaft.
4. Using a suitable torque meter on tool
LRT-41-005, check and record torque to turn
mainshaft input gears.
5. Tighten the intermediate shaft nut in small
stages checking the torque to turn the gears
until the mainshaft input gear torque to turn
figure recorded in operation 4 has increased by
1.25 Nm (10 lbf.in ).
CAUTION: Take great care not to
overtighten nut as this will cause
excessive bearing pre-load. If torque to
turn figure is inadvertently exceeded, a new
collapsible spacer must be fitted.
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