LT230Q TRANSFER BOX. Manual — part 14
TRANSFER BOX
OVERHAUL
39
Rear output housing
1. Apply Hylosil RTV 102 sealant to mating flange
of rear output housing.
2. Fit rear output housing to main casing.
NOTE: Dowel located.
3. Apply Loctite 290 to threads of bolts and
shoulder bolt.
4. Fit washers to 2 bolts.
5. Fit bolts and tighten by diagonal selection to 25
Nm (18 lbf.ft).
6. Fit output flange, new felt and steel washers to
output shaft.
7. Fit a new self-locking nut.
8. Position propeller shaft flange holding tool
LRT-51-003 to output flange.
9. Restrain flange, tighten nut to 162 Nm (120
lbf.ft).
10. Lubricate a new ’O’ ring with recommended oil
and fit to vehicle speed sensor - if fitted.
11. Fit vehicle speed sensor - if fitted.
12. Fit and tighten Allen screw.
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OVERHAUL
Differential bearing pre-load
1. Position high/low selector shaft and fork to
differential ensuring that fingers of selector fork
are located in high/low selector sleeve.
2. Position high/low selector shaft and differential
in main casing ensuring that splines of rear
output shaft are engaged in differential.
3. Position new differential front bearing outer
track on bearing ensuring that track is seated
squarely.
4. Position setting block, tool LRT-41-014/3 on
main casing.
5. Screw pillar LRT-41-014/4 into tapped hole in
main casing.
6. Assemble DTI LRT-99-006 to pillar.
7. Position stylus of DTI to setting block, zero
gauge.
8. Position stylus of gauge on front bearing outer
track, record reading obtained.
9. Position stylus of gauge on opposite side of
bearing track, record reading obtained.
CAUTION: Ensure that bearing track is not
disturbed when carrying out above
operations.
10. Establish average of the 2 readings, record
figure obtained.
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11. Position front output housing as shown.
12. Position depth block, tool LRT-41-014/2 and
cross-bar LRT-41-014/1 on front output
housing.
13. Position DTI LRT-99-006 on cross-bar
LRT-41-014/1 .
14. Zero DTI on depth block LRT-41-014/2 .
15. Position DTI to cross-bar LRT-41-014/1 ,
record reading obtained.
16. Remove tools.
17. Using the formula:
3.05 mm (0.120 in) + B - A = D where:
B = Height difference recorded between depth
block and cross bar
A = Average of readings to differential front
bearing outer track
D - Thickness of shim required to give
differential bearing pre-load of 0.05 mm (0.002
in)
18. From resultant figure obtained, select
appropriate thickness shim from the range
available.
NOTE: Shims are available from 2.00 to
3.25 mm (0.08 to 0.13 in) thickness, rising
in increments of 0.05 mm (0.002 in).
19. Retain selected shim and differential front
bearing outer track with front output housing.
20. Carry out assembly of front output housing
-
See Component assembling.
Front output housing
1. Apply Hylosil RTV 102 sealant to mating flange
of front output housing.
2. Fit front output housing ensuring that splines of
output shaft are engaged in differential and that
internal splines of dog clutch are engaged with
teeth of output shaft.
3. Apply Loctite 290 to threads of bolts.
4. Fit bolts noting that longest bolt is inserted
through high/low selector finger housing.
5. Tighten bolts by diagonal selection to 25 Nm
(18 lbf.ft).
6. Fit output flange, new felt and steel washers.
7. Fit a new self-locking nut.
TRANSFER BOX
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8. Position propeller shaft flange holding tool
LRT-51-003 to output flange.
9. Restrain flange, tighten nut to 162 Nm
(120 lbf.ft).
10. Compress differential lock selector spring and
fit to selector fork.
11. Locate fingers of selector fork in groove in dog
clutch.
12. Fit differential lock selector shaft ensuring end
of shaft is located in recess in rear of housing.
13. Rotate selector shaft until the two flats for the
retaining clips are at right angles to the cover
plate mating face.
14. Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
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