Fitting a Ashcroft ATB to LT230, parts list and fitting questions.

[alien]

Greetings to all within the AULRO Brains Trust:)
I've decided I want to drop my transfer box off in early in 2016.
For the record, early MY12 defender, 2.2ltr, 6speed with a LT230


I want to check the gearbox->transfer box splines for wear and lubrication.
I have read that some have failed as no lube was applied at the assembly point.
Q= Is there a modification that can be done to overcome this?


As it will be out I'll do the seals(yes it's got a minor leak) while it's all accessible.
I've learnt in the past if you are doing seals etc. it's worth checking the centre diff shims also, I wore out a set in the now gone Disco.
I have a plan to eliminate doing this in the future and remove the centre diff weak point.
After lots of searching and reading I have been given the approval to fit a Ashcroft ATB :D
For those that have not heard of them these 2 posts and internal links where handy...
http://www.aulro.com/afvb/technical-chatter/227236-serious-backward-step.html
http://www.aulro.com/afvb/technical-chatter/207166-review-ashcroft-lt230-atb-centre-diff-2.html


Doing the read through the manual's and a search or 5 it seems fairly straight forward on the surface.
I cant' find the finer details to a question though.
I'll get the 2 new associated bearings and a lock nut as a matter of course.
I have access to a press via my son so fitting the bearings should be easy.
In the RAVE it uses special tools to do a end float/pre load check once it's all together.
Q=Can this be done on the workshop bench with out the special tools?
Being a new shaft assembly I assume this would be more critical then if just replacing the bearings on the original set up on a rebuild.


The parts list...
Ashcroft ATB X1.
Seal/gasket kit X1.
Centre diff shaft bearings X2
Centre diff shaft lock nut X1
Gasket sealant.
Loctite.
Oil.


If anyone has any answers to my questions or tips to help this along I'll happily listen.


PS.
I have had an after thought for the usual intermediate shaft leak.
Q=Should I fit a sleave in the housing as is done on the worn housing repair or wait for a few years to see if it leaks again?
Q=If I do how hard is it to do at home or is at a send out job?


Thanks in advance,
Cheers, Kyle.

[justinc]

Hey Kyle gimme a call 0408995635. Puma atb fitting is a specialty of mine ...😕

[sierrafery]

I can't give you advice about the procedures cos this work(ATB and master rebuild kit) was carried out by my mechanics but one tip i can give you is to fit a HD cross pin too Ashcroft Transmissions (http://www.ashcroft-transmissions.co.uk/diy-rebuild-kits/lt230-rebuild-kits/hd-cross-pin.html) and the final result will be the best then

[rick130]

I can't give you advice about the procedures cos this work(ATB and master rebuild kit) was carried out by my mechanics but one tip i can give you is to fit a HD cross pin too Ashcroft Transmissions (http://www.ashcroft-transmissions.co.uk/diy-rebuild-kits/lt230-rebuild-kits/hd-cross-pin.html) and the final result will be the best then


Err, you can't fit the HD cross pin if you are fitting an ATB. ;)


The open centre diff is being replaced so there's no need (and no where to install) any form of cross pin. :D

[Disco Muppet]

Take lots of pics, I'm tossing up between my gf's murderous wrath and one of these in my stocking :D

Sent from my HTC One using AULRO mobile app

[rick130]

Take lots of pics, I'm tossing up between my gf's murderous wrath and one of these in my stocking :D

Sent from my HTC One using AULRO mobile app


Muppet, as has often been quoted on this very board;

" 'tis easier to ask forgiveness than seek permission"


:D

[sierrafery]

Err, you can't fit the HD cross pin if you are fitting an ATB. ;)


The open centre diff is being replaced so there's no need (and no where to install) any form of cross pin. :D

:bat: it seems that my mechanic needed one for his car then and knowing how dumb i am in this area made me buy it :mad: ... it happens when you are too nice with them:cool:

[alien]

Hey Kyle gimme a call 0408995635. Puma atb fitting is a specialty of mine ...😕
Thanks Justin,
I'll text tomorrow afternoon(Monday) before I ring so I don't interrupt your work load to much.


Take lots of pics, I'm tossing up between my gf's murderous wrath and one of these in my stocking :D

Sent from my HTC One using AULRO mobile app
That will slow the procedure a little but if I remember I'll get some.
Of course you could come and help so you'll know what's involved to do yours:p

[rick130]

:bat: it seems that my mechanic needed one for his car then and knowing how dumb i am in this area made me buy it :mad: ... it happens when you are too nice with them:cool:

Oops ! :o

[Disco Muppet]

Muppet, as has often been quoted on this very board;

" 'tis easier to ask forgiveness than seek permission"


:D

True, but I have to match what I spend on my car with what I spend on her, and it's getting expensive :eek: :p







Of course you could come and help so you'll know what's involved to do yours:p

Don't say that, I just might :p

Sent from my HTC One using AULRO mobile app

[roverrescue]

With regards to measuring endfloat I found it easy enough using some metal scraps bolted to the case a mag base and DTI. Having said all that I found and would also presume shimming is to take up tolerances in the case more so than the shaft. I ended up using the same shims when upgrading to ATB.

To sleeve the intermediate you will need a lathe to make the sleeve and a mill with boring bar to machine the case. I turned my sleeve out of 4140 as it was sitting on the shelf. The case milling like most mill jobs took ten times as long to set up and dial in as to machine. Noel (Ancientmariner) has some great pictures in his fantastic zuzu build up showing the sleeving of the case. I just followed his lead.

Steve

[rick130]

Interesting Steve.
I was going to ask Justin how he does it.

I also used the same shims for the centre diff and ended up using a gasket under the output housing to get the pre-load right, in this case using the old school string around the gear and a spring balance to measure the load. (fitting Maxi Drive low range gears at the same time.)

Used the dial gauge on the input shaft to measure the end float then added shims for pre-load.

Mixing both ways seems to have worked.

As for the bush I farmed it out to a local (100km away at the time) machine shop.
The only downside was I forgot to get them to machine a small lead on the bore, they made the shaft to bore clearance almost a press fit, it's a good push fit (like a gudgeon pin) and so the O ring was all but impossible to get in cleanly.

It's all worth doing just to reduce the driveline slop, let alone enjoying the increased driveability.

[rick130]

True, but I have to match what I spend on my car with what I spend on her, and it's getting expensive :eek: :p



Ouch ! :o

[alien]

Looks like I'm committed to doing this now.
I ordered the parts from Ashcroft Monday.
I got an invoice and paid Tuesday with the box of parts on my bench now, just on 7 days.
If I had been home yesterday with Christmas deliveries it would have been 6 days.


Thankyou to those who posted and JC for his time on the phone:)

[justinc]

Looks like I'm committed to doing this now.
I ordered the parts from Ashcroft Monday.
I got an invoice and paid Tuesday with the box of parts on my bench now, just on 7 days.
If I had been home yesterday with Christmas deliveries it would have been 6 days.


Thankyou to those who posted and JC for his time on the phone:)

Wow thats great freight service!!!☺☺

Glad to be of assistance kyle just call if you have any questions☺

Jc

[alien]

With thanks to help offered through this thread the job has been completed, a trip or 2 got in the way.
Disco 3 Doors and Mick_Marsh offered to help so over the last long weekend we completed the job, thanks guys.


No photo's where taken and the job was managed without special tools but they would make life much easier.
The borrowed press was a must use item.
The adaptor shaft had minimal wear but was dry with 124'000Km.


The quick drive with the ATB has impressed me both on asphalt and high speed dirt roads.


This is what I found in the removed centre diff...
http://www.aulro.com/afvb/attachments/technical-chatter/108751d1462084909t-what-acceptable-service-life-lt230-centre-diff-shims-image.jpg (http://www.aulro.com/afvb/attachments/technical-chatter/108751d1462084909-what-acceptable-service-life-lt230-centre-diff-shims-image.jpg)
I've asked a service life question in a new thread...
http://www.aulro.com/afvb/technical-chatter/235335-what-acceptable-service-life-lt230-centre-diff-shims-post2526679.html#post2526679

[Tombie]

If we had known Basil and I would have stayed another night in Melbourne and dropped in!

[alien]

If we had known Basil and I would have stayed another night in Melbourne and dropped in!
If your didn't try and "fly in" under the radar you would have got an invite:p