Reassembly (page 2 of 9)

Make

Land Rover

Model

Discovery II (UK)

Section

Overhaul

Transfer box - LT230SEReassembly · page 2 of 9

4. Using a micrometer, measure the width of each bearing inner track.
5. Record each reading as measurement 'A' and 'B', both measurements should fall within the range of 21.95 to 22.00 mm (0.864 to 0.866 in).
6. Fit inner bearing track 'A' onto tool LRT-41-017 and position intermediate gear cluster onto bearing 'A'.
7. Fit inner bearing track 'B' to intermediate gear, apply finger pressure to bearing inner track and rotate intermediate gear 5 to 10 turns to settle in bearing rollers.

8. Attach a DTI to base of tool LRT-41-017 , zero gauge on top of tool post and take 2 measurements at 180° of the step height between the top of the tool post and the bearing inner track. Take an average of the two readings and record this as measurement 'C'. Measurement 'C' should be in the range of 0.15 to 0.64 mm (0.006 to 0.025 in).
9. Using the formula 103.554 mm (4.0769 in) -'A'- 'B'-'C', calculate the length of bearing spacer required. From the result of the calculation round DOWN to the nearest length of spacer available to give a correct bearing pre-load of 0.005 mm (0.002 in). 40 spacers are available ranging in length from 58.325 mm (2.296 in) to 59.300 mm (2.335 in) rising in increments of 0.025 mm (0.001 in).
10. Remove intermediate gear assembly from tool LRT-41-017.
11. Lubricate and fit bearings and selected spacer to intermediate gear.
12. Position tool LRT-41-004 through bearings and spacer.
13. Lubricate and fit 'O' rings to main casing and intermediate shaft.
14. With assistance, position intermediate gear assembly and fit intermediate shaft.
15. Rotate shaft until retaining plate can be located on flat on shaft.
16. Apply Loctite 290 to threads of retaining plate bolt, tighten bolt to 25 Nm (18 lbf.ft).
17. Fit new intermediate shaft Patchlok nut and tighten to 88 Nm (65 lbf.ft).Do not stake nut at this stage.

24 General