Defender (1993+). Manual — part 54

LT230T TRANSFER GEARBOX

22. Withdraw the centre differential and selector

shaft/fork assembly.

High/low cross - shaft housing removal

Centre differential removal

18.

Remove the six bolts and washers retaining

21.

Remove high/low selector shaft detent plug,

the cross - shaft housing ground lead and

spring and retrieve the ball with a suitable

retaining clip.

magnet.

19.

Remove the cross

-

shaft housing and gasket

discard the gasket.

Front output housing removal

20. Remove the eight bolts and washers and

detach the output housing from the transfer
box casing, taking care not to mislay the
dowel. Remove the gasket and discard.

Rear output housing removal

23.

Remove six bolts and washers and detach the
rear output housing and shaft assembly

from

the transfer casing.

24.

Remove the gasket and discard.

12

REISSUED: FEB

1993

LT230T TRANSFER GEARBOX

Transfer case overhaul - reassembling

29.

If previously removed,

fit

studs and dowels

to

front face

of the transfer casing. Use new

components where necessary.

NOTE: The position of the radial dowel

blade is set in line with the circle which is
formed

by

the front output housing fixing

damage.

Remove

if

replacements

are

holes.

required.

26.

Remove the magnetic drain plug, copper

30. Refit magnetic drain plug with new copper

washer 'and filler/level plug. Discard the

washer and tighten to the specified torque,

washer.

Transfer case, dismantle and overhaul

25.

Inspect the studs and dowels for wear or

loosely

fit

the filler/level plug.

27.

Drive out differential rear bearing track.

28.

Clean all areas of the transfer casing ensuring
all traces

of

'Loctite'

are

removed

from

faces

and threads.

REISSUED: FEB

1993

13

LT230T

TRANSFER GEARBOX

Rear output housing dismantle and overhaul

4.

Remove housing from the vice and drive out

the output-shaft, by striking the flange end of

5.

Carefully lever off the

oil

catch ring using a

6.

Remove and discard the seal from the output

2. Remove output flange with circlip attached.

If

housing using tool 18G 1271

to

avoid

damaging the housing.

1.

Using flange wrench 18G1205 and socket

the shaft.

wrench, remove the flange nut, steel and felt
washers, Ensure flange bolts are fully

screwdriver in the

slot

provided.

engaged in the wrench.

necessary, use a

two

-

legged puller.

NOTE: The circlip need only be released

if

the flange bolts are

to

be

replaced.

7. Using circlip pliers, remove the circlip retaining

the bearing.

8.

Drive out the bearing from the rear

of the

housing.

3.

Remove speedo - drive housing. This can be
eased

out

with a screwdriver.

14

REISSUED:

FEB

1993

I

LT230T TRANSFER

GEARBOX

9. Remove speedometer gear (driven) from its

housing.

10. Remove the ' O ' ring and oil seal and discard.

16. Carefully coat the lips

of

the seal with clean

grease and refit oil catch ring onto output

17. Fit the ' O ' ring and oil seal (lip side inwards)

to

speedometer housing.

18. Lubricate the ‘O’

ring

and seal with

oil,

19.

Locate speedometer gear (driven) in housing

11.

Slide

off

spacer and speedometer drive gear

housing.

from output shaft.

12. Clean all parts, replace the

'0' ring, oil seals,

felt seal and flange nut. Examine all other
parts

wear or damage and renew, if

necessary.

and press into position.

Reassembling

rear output housing

13. Press output bearing into the housing.

Do not

use excessive force.

To facilitate fitting the

bearing, heat the output housing case.

(This

is

not to exceed 100°C (212°F)).

14.

Retain bearing with circlip, using circlip pliers.

15. Pre-grease between the seal lips and fit new

seal, lip side leading, using

tool

18G1422. The

seal should just make contact with the bearing
circlip.

REISSUED: FEB

1993

15