Mainshaft input gear (Transfer box - LT230SE)

Transfer box interlock solenoid - Automatic gearbox vehicles An interlock solenoid is fitted for North America and Japan. The solenoid is located on the top of the transfer box main casing on vehicles up to 03 model year or on the selector lever assembly on vehicles from 03 model year. The solenoid is connected to the transfer box relay which, in turn, is controlled by the IDM. The purpose of the solenoid is to prevent neutral being selected on the transfer box when the ignition key is removed, thereby locking the box in either high or low ratio.

Mainshaft input gear

The gearbox output shaft is splined into the mainshaft input gear which is supported by taper roller bearings.

Input gear bearing pre-load is achieved by the use of a selective shim located in the bearing housing.

Intermediate gears

The intermediate gear cluster is supported by the taper roller bearings located at each end of the cluster and runs on the intermediate shaft which, in turn, is supported at the front and rear by the main casing.

A selective spacer, positioned between the gears, pre-loads the intermediate gear bearings when the intermediate shaft nut is tightened sufficiently to achieve the correct 'torque to turn' of the intermediate gears.

On vehicles from 03 model year, the circlips used to retain the bearings in the intermediate gear are deleted. The bore of the intermediate gear is machined with a shoulder at each end to locate the bearings.

Differential assembly

The differential assembly is supported at the front and rear by taper roller bearings, the front bearing outer track is located in the front output housing and the rear bearing outer track is located in the main casing by the rear output housing. Bearing pre-load is achieved by means of a selective shim located in the front output housing.

The differential rear shaft carries the low range gear, high/low selector sleeve and hub, high range gear and bush and the differential rear bearing; these components being secured to the shaft by a special staked nut.

The differential assembly comprises front and rear half carriers with integral shafts and with sun and planet gears mounted on cross shafts within the half carriers. Dished, non-selective thrust washers control the engagement of the planet gears with the sun gears, whilst selective thrust washers are used to control engagement of the sun gears and 'torque to turn' of the differential. The differential carrier halves are bolted together, a retaining ring providing positive location of the cross shafts.

The high/low selector shaft and fork are located at the side of the differential, movement of the shaft, fork and selector sleeve being controlled by the high/low selector finger. A spring loaded detent ball fitted in the main casing, locates in grooves in the shaft.

On vehicles from 03 model year, the selector fork is modified and fitted with a spring assistor and clips to reduce the effort required to move the selector lever.

Front output housing

The front output housing carries the front output shaft and flange, high/low cross shaft, housing and selector and on certain vehicles, the differential lock selector shaft and fork.

The front output shaft is supported in the housing by a single bearing and is splined into the differential front sun gear.

High/low selector

The high/low cross shaft is located in a housing bolted to the top of the output housing and is connected to the high/ low selector finger which locates in a slot in the selector shaft.