Thread: LT230 input gear

Never had a problem fitting a TC with the gear in place, engage the CDL and high range and turn an output flange and it goes in without a hitch. Dunno about the cross drilling though.

Just remove the cover and pull the gear out. If it's drilled it's very obvious.
If pulling the entire TC. Make up 2x 120mm M10 guides. Just cut the hex head off and cut a screwdriver slot in the ends. The TC will just slide into place with a gentle turn of the drive flange. Diff locked first though.

If it's not a drilled gear, check the splines for wear. If the gearbox output shaft splines are worn then it's a box out job. And a lot more work.
Good luck.

Thanks all. I will get into it.
Just bought a four post hoist so I can start this job. I am getting too old to be rolling around under cars.
These modern one piece bodies are a pain as I am used to working from the top with old series Landies

Keith

I pulled my LT230 last weekend. It was fairly simple, just time consuming. I didn't remove the input gear first and came off ok. I used 150mm M10 bolts with the head cut off. To add to that, the gearbox output shaft protrudes 120mm so you want to screw the guide bolts in about 30mm. If they're too long the transfer case won't slide back far enough, although that depends if you remove the handbrake drum.

Since we're on the topic I couldn't figure out where to disconnect the handbrake cable so my drum is hanging under the vehicle! Any tips? It's a Disco.

If you have a hoist I guess you'll have better visibility than me, but there are 4 bolts on the rear and 2 on the front of the LT230 to unbolt from gearbox. 1 was hiding from me for a while...

Originally Posted by Judo

Since we're on the topic I couldn't figure out where to disconnect the handbrake cable so my drum is hanging under the vehicle! Any tips? It's a Disco.

You need to remove the centre console, the outer cable has a simple circlip and the inner is pinned to the lever. No need to remove it though unless your cable is stuffed, just hang up the back plate.

Removing the top of the tunnel allows access to the various pins and bolts from the top too.

Originally Posted by Judo

I pulled my LT230 last weekend. It was fairly simple, just time consuming. I didn't remove the input gear first and came off ok. I used 150mm M10 bolts with the head cut off. To add to that, the gearbox output shaft protrudes 120mm so you want to screw the guide bolts in about 30mm. If they're too long the transfer case won't slide back far enough, although that depends if you remove the handbrake drum.

Since we're on the topic I couldn't figure out where to disconnect the handbrake cable so my drum is hanging under the vehicle! Any tips? It's a Disco.

If you have a hoist I guess you'll have better visibility than me, but there are 4 bolts on the rear and 2 on the front of the LT230 to unbolt from gearbox. 1 was hiding from me for a while...

remove the handbrake drum! cable tie it to one side. can be dangerous if you try and hold on to it whilst removing the tcase. its a 10min job to undo it and tie it to the side. dont need to remove handbrake cable.

make sure CDL stick is to the front of the car, gives you a bit more room to move back.

also, i removed the little housing on top of the gearbox, that the stick comes out of. just 3 screws and lets you move the whole assembly up and down a little to help the manouvring.

i did not remove the input gear. you WILL need to remove centre tunnel in the cabin and the rubber gaiters etc. instead of riveting the metal frame which holds the rubber gaiter down when you put it back together, as someone here did, good idea to just put little bolts in with circlips or similar so you dont have to drill out rivets in future.

i put the rivets back and had to pull the thing apart again a few weeks later as one of the gearbox seals i put in was leaking. front one. i cried a little

Originally Posted by Fausto79

remove the handbrake drum! cable tie it to one side. can be dangerous if you try and hold on to it whilst removing the tcase. its a 10min job to undo it and tie it to the side. dont need to remove handbrake cable.

make sure CDL stick is to the front of the car, gives you a bit more room to move back.

also, i removed the little housing on top of the gearbox, that the stick comes out of. just 3 screws and lets you move the whole assembly up and down a little to help the manouvring.

i did not remove the input gear. you WILL need to remove centre tunnel in the cabin and the rubber gaiters etc. instead of riveting the metal frame which holds the rubber gaiter down when you put it back together, as someone here did, good idea to just put little bolts in with circlips or similar so you dont have to drill out rivets in future.

i put the rivets back and had to pull the thing apart again a few weeks later as one of the gearbox seals i put in was leaking. front one. i cried a little

I'm thinking rivnuts instead of rivets.

I said drum is hanging, but sorry I meant the back plate and shoes. I removed the drum. I removed the transfer box without needing to disconnect the cable or even remove the centre console. I now want to remove the back plate and shoes as they have more oil in them than the transfer box.

Also, now that I've taken the centre console out, I wish I did that before removing the transfer box. Would have been much easier undoing the linkages on top!

Originally Posted by Judo

I'm thinking rivnuts instead of rivets.

I said drum is hanging, but sorry I meant the back plate and shoes. I removed the drum. I removed the transfer box without needing to disconnect the cable or even remove the centre console. I now want to remove the back plate and shoes as they have more oil in them than the transfer box.

Also, now that I've taken the centre console out, I wish I did that before removing the transfer box. Would have been much easier undoing the linkages on top!

sorry my bad. what i actually meant now that you mention it, is the drum i took right off and used it to store bolts etc. it was the shoes and backplate which i had hanging to the side cable tied to the chassis. mine was very clean. so just left it till it was time to put tcase back in.