LT230Q TRANSFER BOX. Manual — part 9
TRANSFER BOX
OVERHAUL
19
Mainshaft input gear
1. Check gear teeth for cracks, chipping and
uneven wear.
2. Check that cross drillings in shaft are clear.
Defender only
3. Check that ends of dog teeth are not
’rounded-off’ or chipped.
High/low cross shaft and housing
1. Check mating surfaces of cross shaft and
drilling in housing for wear.
2. Check core plug in housing for signs of
leakage or corrosion, apply Loctite 326 to
replacement plug.
3. Check high/low selector finger for wear.
4. Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in)
TRANSFER BOX
20
OVERHAUL
Front output housing and differential lock
selector
1. Check bearing track recesses in housing for
damage, rectify or replace housing as
necessary.
2. Check differential lock selector finger shaft and
drilling in housing for wear.
3. Check differential lock selector finger for wear.
4. Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in)
5. Check differential lock selector finger groove
width in differential lock selector shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64
in)
6. Check detent grooves in differential lock
selector shaft for wear.
7. Check differential lock detent ball for flat spots.
8. Check detent spring for distortion.
9. Check differential lock selector fork for cracks
and wear.
10. Check differential lock selector fork finger
width:
Finger width = 7.92 to 7.97 mm (0.311 to 0.313
in )
11. Check differential lock selector fork spring for
distortion and clips for wear and damage.
12. Check spring free length:
Free length = 84.58 mm (3.33 in)
TRANSFER BOX
OVERHAUL
21
13. Check dog clutch internal teeth and grooves for
wear and damage.
14. Check dog clutch selector fork groove width:
Groove width = 8.05 to 8.20 mm (0.32 to 0.33
in)
15. Check threads and splines of output shaft for
damage and wear.
16. Check dog clutch teeth on shaft for wear and
damage.
Rear output housing
1. Check bearing track recess in housing for
damage, rectify or replace housing as
necessary.
2. Check speedometer drive and driven gears for
damage and wear.
3. Check splines and threads of output shaft for
damage and wear.
TRANSFER BOX
22
OVERHAUL
Main casing
1. Check bearing track recesses in main casing
for damage, rectify or replace casing as
necessary.
2. Remove drain plug, discard sealing washer.
3. Fit new sealing washer, fit drain plug and
tighten to 30 Nm (22 lbf.ft).
4. Remove filler plug, check threads for damage.
5. Fit but do not fully tighten filler plug.
6. Check that locating dowels are fitted in casing
and that blade of front output housing dowel is
positioned as shown.
7. Remove oil temperature switch - if fitted,
remove sealant from threads of switch and
main casing.
8. Apply Hylosil PL32 sealant to threads, fit and
tighten switch.
9. Check high/low detent ball for flat spots.
10. Check detent spring for distortion.
Mainshaft input gear bearing housing
1. Check bearing track recess in housing for
damage, rectify or replace housing as
necessary.
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