Thread: Output shaft differences between ZF auto and LT77?

I thought they were the same, this is going to sound silly, but are you using the spud shaft for the ZF?

Maybe there are some burrs on either the output shaft or inside the input gear of the LT230

I had a bit of trouble fitting the LT230 to the LT77 in my tdi disco and found that with the centre diff locked, wiggling the output flanges while pushing the box on helped locate it better

Gavin, if it goes on all bar about 25mm, then check very carefully the spline depth, you may have bottomed out in the input gear. There were several different input gear splined lengths, the internal spline that is in the transfer case.

JC

Originally Posted by jazzaD1

I thought they were the same, this is going to sound silly, but are you using the spud shaft for the ZF?

Maybe there are some burrs on either the output shaft or inside the input gear of the LT230

I had a bit of trouble fitting the LT230 to the LT77 in my tdi disco and found that with the centre diff locked, wiggling the output flanges while pushing the box on helped locate it better

Tried all the wiggling stuff while turning the output, and no burs in the output shaft. What is the spud shaft you mentioned?

Originally Posted by justinc

Gavin, if it goes on all bar about 25mm, then check very carefully the spline depth, you may have bottomed out in the input gear. There were several different input gear splined lengths, the internal spline that is in the transfer case.

JC

Thanks JC, but I'm not getting anywhere close to that - I just can't get the shaft to engage with the input on the TC... I'll measure that though before I try again.

Cheers - Gav.

this is the spud shaft i'm talking about, it adapts the output shaft of the ZF to a 10 spline shaft for the LT230

also if you need to, you could remove the input gear from the transfer case to see if you can get it to mesh with the ZF

Gav, It might be burred like Jazza suggests then. If the spline wear is excessive on either external or internal splines, then you will have the devils own trying to fit another or worse still a new one in.

JC

Yep, that is there. Don't really want to pull the input shaft out the TC - I've only just put it all back together.... or does the spud shaft come off the box easily?

I'll have another crack in the morning and failing that I'll pull it apart again. Another forum member is coming over to give me a hand, so hopefully between us we can get it to work.

Originally Posted by justinc

Gav, It might be burred like Jazza suggests then. If the spline wear is excessive on either external or internal splines, then you will have the devils own trying to fit another or worse still a new one in.

JC

I'll have a closer look at that. There was no easily visible wear on the LT77 output shaft when I removed it and none evident on the auto. I didn't check the input shaft splines closely while I had everything apart though.

I'll see what the new day brings.

Thanks for all the advice - Gav

Are you using guide pins to refit the transfer case? Cut the heads off two 200mm long 10mm bolts and install them in the back of the trans. These help the transfer to go on straight and not damage the seal. Spin them out when the other bolts are in and put the last two bolts in.