LT230Q TRANSFER BOX. Manual — part 11
TRANSFER BOX
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36. Invert assembly in vice and then insert rear
output shaft into rear half carrier, check that
gears rotate freely.
37. Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
38. Fit transmission brake drum to output flange,
secure with 2 nuts.
39. Carry out load to turn check using same
method as for front half carrier.
40. When load to turn figure is correct, record final
figure.
41. Upon completion, fit sun gear and selected
thrust washer to front half carrier.
42. Fit front half carrier ensuring that alignment
marks are together.
43. Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
44. With differential assembled, fit rear output shaft
and brake drum and check overall load to turn.
This should be approximately equal to total
load to turn figure of both front and rear half
carriers added together:
Used gears = 0.90 kg (2.0 lb)
New gears = 3.44 kg (7.6 lb)
45. Secure rear half carrier in a soft-jawed vice.
46. Fit a new front bearing using tool LRT-41-008.
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47. Support front half carrier in a soft-jawed vice.
48. Fit low range gear ensuring that dog teeth on
gear are towards threaded end of shaft.
NOTE: Use a suitable hollow mandrel to fit
gear if it is tight on splines.
49. Fit high/low hub ensuring that alignment mark
made during dismantling is towards threaded
end of shaft.
50. Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
51. Fit bush to high range gear ensuring that collar
on bush is on opposite side of gear to the dog
teeth.
52. Fit high range gear and bush ensuring that
collar on bush is towards threaded end of
shaft.
53. Fit a new rear bearing using tool LRT-41-008.
54. Fit a new bearing retainer nut, tighten to 72 Nm
(53 lbf.ft) using tool LRT-41-007.
CAUTION: Do not stake nut at this stage.
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55. Slide high/low selector sleeve and hub away
from low range gear.
56. Using feeler gauges, determine clearance
between low range gear and high/low hub:
Clearance = 0.05 to 0.15 mm (0.002 to 0.006
in)
57. If clearance is not as specified, fit a new low
range gear and high/low hub and re-check.
58. Slide high/low selector sleeve and hub away
from high range gear.
59. Using feeler gauges, determine clearance
between high range gear and high/low hub:
Clearance = 0.05 to 0.15 mm (0.002 to 0.006
in)
60. If clearance is not as specified, fit new high
range gear and high/low hub and re-check.
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61. Using a round nosed punch, stake collar of nut
into recess in differential shaft.
Main casing
1. Fit a new differential rear bearing track using
tool LRT-51-009.
2. Using a straight edge and feeler gauges, check
that bearing track is recessed 1.0 mm (0.04 in)
below outer face of main casing.
3. Using a suitable mandrel, fit a new mainshaft
input gear bearing track.
CAUTION: Ensure bearing tracks are
seated squarely in recesses.
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