LT230 Transfer Box Overhaul

[Phillip]

I need to pull the gearbox out of the vehicle and i was considering overhauling the transfer box. Has anyone done this and how difficult is it? I think getting the right pre-load on the bearings would be the tricky bit or do you use the old shims?

[Disco_owner]

Hi Phillip

I've never done an LT230 Overhaul , however if you decide to go ahead with it let me know because I can get you really top quality bearings at almost Cost from a Mate who owns a Ball bearing Buisness.

[HSVRangie]

Reco a LT230 is pretty easy.

Follow manual for specs.

Did mine a few years ago.

MIchael.

[MacMan]

I'll be splitting one shortly to inspect and check health of gears and bearings. I'll take plenty of pics and perhaps even video some of it.

I think the most useful thing will be recording the work-arounds in the absence of the "special tools" detailed in the manual, and how much can be done with generic pullers.

[DaveS3]

I'm going to have a go at mine as well next month once everything else is done.

Has anyone sussed a good supplier of a rebuild kit & new Cross drilled input gear?/

Cheers
Dave.

[HSVRangie]

pull it to bits sat morn take all bearings seals to favorite bearing sales purchase new items.

gasket kit and shims from favorite L/Rover parts supplier.

if gear is in good condition drill it yourself.

I used 2 hi tungsten carbide drill bits. PIA slow but not to bad.

have fun.

[MinniTheMoocha]

I'll be splitting one shortly to inspect and check health of gears and bearings. I'll take plenty of pics and perhaps even video some of it.

I think the most useful thing will be recording the work-arounds in the absence of the "special tools" detailed in the manual, and how much can be done with generic pullers.

I would be interested in how this goes as my intermediate shaft is leaking. I am just concerned that as its my daily runner and not having the tools I won't be able to get it back together in time if I do it over a weekend.

thanks

[MacMan]

In true form, what started as a "not going to bother about all the bearings, will just reseal it and throw it in" has turned into "while I am there I might as well do the job properly"... Just waiting on pricing for seals and some bearings VS doing the whole lot.

I'll be doing the LT77 at the same time - my thinking there is that it might be worth spending more money and time on the LT77 since it's harder to get at later down the track and the whole objective here is to make the Disco easier for Mrs MacMan to drive. The LT230 has nothing to do with that current problem, but I don't like doing jobs by halves.

[MacMan]

I received my care package from Karcraft this morning:

New clutch
LT77S overhaul kit
LT230 overhaul kit
Double lipped oil seals for oil fed wheel bearing conversion
New swivel seals

And I have in a box in the garage a full set of Timken wheel bearings and carrier bearings for both diffs.

I'll attempt to document it all and take some pics. Might have to set up a blog!

[JohnM]

Hi Macman,

Which clutch kit did you go with - heavy duty or standard?
What does the transfer case overhaul kit include?

Up for a similar job very soon.

Thanks

[MacMan]

Clutch is just the standard for a 3.9 and 4.2 V8. I expect the clutch in the Disco at the moment will be absolutely fine, but I'm doing it just because it's all there to do.

KC810 G/BOX OVERHAUL KIT - L/ROV LT230T (TRANSFER BOX)
FRC5564 - BEARING - MAINSHAFT - L/ROVER (LT230)(T/CASE) x 2
FRC6968 - DIFF GEAR WASHER - L/ROVER (CENTRE DIFF)(LT77+727) x 4
FRC7437 - SPACER - INTERMEDIATE SHAFT - L/ROVER (LT230)
FRC7871 - BEARING - OUTPUT - L/ROVER (LT95+LT230)
FRC7970 - NUT - BRG RETAINER - L/ROVER (LT230)
FY108046 - NUT - L/ROVER
NY120046 - NUT - L/ROVER x 2
PRC2911 - SWITCH - REVERSE+DIFF LOCK - L/ROV DEF+DISC+R/ROV
R606474 - BEARING - OUTPUT - TRANSFER CASE - L/ROVER (LT230)
RTC3890 - GASKET SET - G/BOX TRANSFER CASE - L/ROVER (LT230)
STC1130 -. BEARING - VARIOUS - L/ROVER x 2
STC3185 - BEARING - INTERMEDIATE SHAFT - L/ROVER (LT230) x 2
UYH500020 - NUT - INTERMEDIATE SHAFT - L/ROVER (LT230)

The only additional parts I have added were the o-rings for the intermediate shaft.

Looks like I'll be in the shed this weekend!

[MacMan]

I spent today making some tools simplify things and got to starting to split the cases after dinner. Also bought a small hydraulic assist puller and press.

I've taken heaps of photos already, but I guess have another 5 or so hours before everything is a apart.

[Phillip]

I finished mine on the weekend and I followed the spec's to the letter, well almost. I made some dummy bearings to fit into the front and rear output housings so I could measure what pre-load spacer was required. I used a spring balance to measure the pre-load for the intermediate shaft bearings and I also machined out the main housing and fitted a sleeve for the intermediate shaft. My transfer case was originally put together without gaskets and went back together the same way. I thought it would be a difficult job but it was reasonably easy. So hopefully it will be all fine.

[rick130]

Hi Macman,

Which clutch kit did you go with - heavy duty or standard?
What does the transfer case overhaul kit include?

Up for a similar job very soon.

Thanks

I used an AP kit on JustinC's advice twelve months ago rather than the Valeo kit.

Remember to order the thrust race staples and slave cylinder pushrod retaining clips on top of a new clutch fork, flywheel spigot bush and the clutch kit, get the flywheel machined and soak the spigot bush in warm-hot oil for a few hours or overnight.

[Pedro_The_Swift]

I reckon there'd be around 15kg's you could lose off the flywheel---:whistling:

[MacMan]

I used an AP kit on JustinC's advice twelve months ago rather than the Valeo kit.

The kit I have is an AP kit.

Started pulling the case apart last night. I am now glad that I am doing it properly rather than just making do with seals.

The rear output housing was an absolute BEAR to get off!

[spudboy]

Too late for Phillip as he's already finished his, but here's a couple of good links about doing work on the LT230:

Replacing an LT230 Transfer box - LR4x4 - The Land Rover Forum (http://forums.lr4x4.com/index.php'showtopic=14601&hl=lt230)

LT230 rear bearing and seal replacement - LR4x4 - The Land Rover Forum (http://forums.lr4x4.com/index.php'showtopic=6917&hl=lt230)

Lots of photos and descriptions.

HTH
David

[rick130]

I reckon there'd be around 15kg's you could lose off the flywheel---:whistling:

:rolleyes:

[specwarop]

What manual have you guys been using to rebuild the LT230?