LT230 Transfer Box Overhaul

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!

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.

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.

Quote:

---

Originally Posted by 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

---

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.

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

Quote:

---

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!

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

LT230 rear bearing and seal replacement - LR4x4 - The Land Rover Forum

Lots of photos and descriptions.

HTH
David

Quote:

---

Originally Posted by Pedro_The_Swift

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

---

:rolleyes:

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