Thread: lt95 rebuild, anyone done it?

lt95 is the pick of the boxes... not particulalry hard to rebuild compared to some modern boxes, pay attention to how it comes apart and do that backwards with new pieces to put it back, if you dont have the TRB conversion and the Tcase side intermediate shaft or bearings are being done its worth the effort.

Shim it to the tight side (I like to go them about 1/2 way between nominal and maximum tolerance), be sure to get the metal gears and drive for the pump, go easy on the sealant and make sure all the seal running surfaces are perfect before you fit them up.

thanks for the info mate, away to do some reserch in to what a trb kit is. ever messed about with the lt230s? im ashamed to admit that i dont know exactly how transfer cases work and was thinking of leaving it to the pros. or doing a hell of alot of reaserch about them, how hard can it be haha.

Cheers, Andy

I documented most of my rebuild here: http://www.aulro.com/afvb/projects-t...beginners.html
Didn't go into setting up the intermediate shaft as I got hold of a TRB conversion so didn't bother looking at how the standard shaft is shimmed etc.

Stirlsilver has a whole lot of photos and info in a thread about his Stage1, so have a search for that one too.

Transfer boxes are pretty simple - just a 2 speed gearbox, with a center diff.
Once you've got your LT95 sitting on the bench pull the cover off the transfer and have an eyeball in there while you change ranges and have a rotate of the input shaft etc. If it takes you any more than a minute to see how it works then maybe you should just put the cover back on

Double cardan shafts depends on what length you need. D2's had them, and also the Stage1's.
I had one custom made by Tom Woods shafts in the USA. Good universals, greaseable center and rebuildable for a bit over AUD$500 landed. They make and ship within 24hrs of receiving payment and it was landed here within a week so very good service. I think others have had them made locally but not sure of the cost etc.

Steve

Originally Posted by rrc80

thanks for the info mate, away to do some reserch in to what a trb kit is. ever messed about with the lt230s? im ashamed to admit that i dont know exactly how transfer cases work and was thinking of leaving it to the pros. or doing a hell of alot of reaserch about them, how hard can it be haha.

Cheers, Andy

yep, the basics of the Tcase side of the lt95 and the 230 is more or less the same.

having a read through youre post steve, very interesting, just a few questions,

youre talking about a rebuild manual/book, where can i get one?

im guessing when you got the genuine parts you got them from a lr dealership? or can you get them overthe net, as its a real pita for me to get to lr.

there is alot of talk about the lt 95 and 230 being the same thing? i thought the 95 was the gear box and the 230 was the t.case?

cheers, andy

Originally Posted by rrc80

having a read through youre post steve, very interesting, just a few questions,

youre talking about a rebuild manual/book, where can i get one?

im guessing when you got the genuine parts you got them from a lr dealership? or can you get them overthe net, as its a real pita for me to get to lr.

there is alot of talk about the lt 95 and 230 being the same thing? i thought the 95 was the gear box and the 230 was the t.case?

cheers, andy

LT95 is a combined gearbox and transfer in one casing.
The LT230 is a separate transfer case thats used behind other boxes eg the LT77, LT85, and R230.

Maybe where you are getting confused is that people will say the LT230 and the transfer part of the LT95 are basically the same inside. Not to say that they use exactly the same parts, just that they have the same function etc.

I got my parts from a mixture of places. Some local LR, quite a few from LRSeries in the UK (genuine parts for things like synchro rings etc), and some from other suppliers. Just depended on who had what and how much of a hurry I was in.

Steve

ahh thanks that clears it up.

yea iv used lrseries befour there good.

where can i get a rebuild book/guid and a parts manual?

also iv tryed to search what the TRB thing is. im finding alot of info on people putting it in but nothing on what it replaces and why?

cheers, andy

Originally Posted by rrc80

ahh thanks that clears it up.

yea iv used lrseries befour there good.

where can i get a rebuild book/guid and a parts manual?

also iv tryed to search what the TRB thing is. im finding alot of info on people putting it in but nothing on what it replaces and why?

cheers, andy

The LR Rave manuals have the gearbox info in them. LT95 info is in both the RRC manual and the early 110 ones. Buy a CD with them on from the AULRO shop at the top of the page.

TRB shaft is a replacement LT95 transfer case intermediate shaft that has tapered roller bearings (hence TRB ). It replaces the standard intermediate shaft that has bronze shims to take the thrust loads from the gears. These shims wear out and severe wear can cause the drive dogs on the gears to disengage and jump out of gear etc.
The tapered bearings on the TRB shaft take the thrust loads without the wear problem of the shims.

Steve