Transfer Box Assembling

Transfer Box Assembling

1. Lubricate all components with recommended oil.

CAUTION: Where use of gaskets is specified, gaskets must be fitted; do not use sealant.

Mainshaft input gear bearing pre-load







1. Position mainshaft input gear assembly in main casing.
2. Up to serial no. 288709E: Fit a new mainshaft input gear bearing housing gasket, dry on main casing.
3. All transfer boxes: Fit mainshaft input gear bearing housing ensuring reference marks are aligned.
4. Fit 2 M10 x 25 mm bolts and tighten to 25 Nm (18 ft. lbs.).
5. Position suitable DTI with stylus of gauge contacting end of mainshaft, push mainshaft rearwards and zero gauge.
6. Push mainshaft forwards and note gauge reading.
7. Calculate thickness of shim required using the formula A + B + C = D where:
A = Thickness of installed shim - 3.15 mm (0.12 in)
B = Recorded end-float
C = Required pre-load - 0.05 mm (0.002 in)
D = Thickness of shim required

8. If an alternative shim is required to establish correct end-float, proceed as follows:

NOTE: Do not remove mainshaft input gear bearing housing if bearing pre-load is correct.

9. Remove 2 bolts, remove mainshaft input gear bearing housing.

NOTE: Up to serial no. 288709E, retain gasket on main casing.

10. Using a soft metal drift, carefully drive input gear bearing track out of bearing housing, remove shim.

CAUTION: If bearing track is damaged during this operation, a new track must be fitted.

11. Select required shim from the range available.

NOTE: Shims are available from 3.15 to 4.00 mm (0.12 to 0.16 in) thickness rising in increments of 0.05 mm (0.002 in).

12. Fit selected shim and using a suitable mandrel, fit input gear bearing track.
13. Fit mainshaft input gear bearing housing and temporarily secure using 2 M10 x 25 mm bolts tightened to 25 Nm (18 ft. lbs.).

Rear output housing
1. Up to serial no. 288709E: Position a new gasket, dry on main casing.
2. From serial no. 288709E: Apply Hylosil RTV 102 sealant to mating flange of rear output housing.







3. Fit rear output housing to main casing.

NOTE: Dowel located.

4. Apply Loctite 290 to threads of bolts and shoulder bolt.
5. Fit washers to 2 bolts.
6. Fit bolts and tighten by diagonal selection to 25 Nm (18 ft. lbs.).
7. Fit output flange, new felt and steel washers to output shaft.
8. Fit a new self-locking nut.







9. Position propeller shaft flange holding tool LRT-51-003 to output flange.
10. Restrain flange, tighten nut to 162 Nm (120 ft. lbs.).







11. Lubricate a new 'O' ring with recommended oil and fit to vehicle speed sensor - if fitted.
12. Fit vehicle speed sensor - if fitted.
13. Fit and tighten Allen screw.

Differential bearing pre-load







1. Position high/low selector shaft and fork to differential ensuring that fingers of selector fork are located in high/low selector sleeve.
2. Position high/low selector shaft and differential in main casing ensuring that splines of rear output shaft are engaged in differential.







3. Position new differential front bearing outer track on bearing ensuring that track is seated squarely.
4. Position setting block, tool LRT-41-014/3 on main casing.
5. Screw pillar LRT-41-014/4 into tapped hole in main casing.
6. Assemble DTI LRT-99-006 to pillar.
7. Position stylus of DTI to setting block, zero gauge.







8. Position stylus of gauge on front bearing outer track, record reading obtained.
9. Position stylus of gauge on opposite side of bearing track, record reading obtained.

CAUTION: Ensure that bearing outer track is not disturbed when carrying out above operations.

10. Establish average of the 2 readings, record figure obtained.







11. Position front output housing as shown.
12. Up to serial no. 288709E: Position a new gasket, dry, on front output housing.
13. Position depth block, tool LRT-41-014/2 and cross-bar, tool LRT-41-014/1 on front output housing.
14. Position DTI LRT-99-006 on cross-bar LRT-41-014/1 .
15. Zero DTI on depth block LRT-41-014/2.
16. Position DTI to cross-bar LRT-41-014/1, record reading obtained.
17. Remove tools.
18. Up to serial no. 288709E: Remove and retain gasket.
19. Using the formula:
3.05 mm (0.120 in) + B - A = D where:
B = Height difference recorded between depth block and cross bar
A = Average of readings to differential front bearing outer track
D = Thickness of shim required to give differential bearing pre-load of 0.05 mm (0.002 in)

20. From resultant figure obtained, select appropriate thickness shim from the range available.

NOTE: Shims are available from 2.00 to 3.25 mm (0.08 to 0.13 in) thickness rising in increments of 0.05 mm (0.002 in).

21. Retain selected shim and differential front bearing outer track with front output housing.
22. Up to serial no. 288709E: Retain gasket with front output housing.
23. Carry out assembly of front output housing - See Component assembling.

Front output housing







1. Up to serial no. 288709E: Fit gasket used when determining differential bearing pre-load, dry, to main casing.
2. From serial no. 288709E: Apply Hylomar RTV 102 sealant to mating flange of front output housing.

All transfer boxes

3. Fit front output housing ensuring that splines of output shaft are engaged in differential and that internal splines of dog clutch are engaged with teeth of output shaft.
4. Apply Loctite 290 to threads of bolts, fit bolts noting that longest bolt is inserted through high/low selector finger housing.
5. Tighten bolts by diagonal selection to 25 Nm (18 ft. lbs.).
6. Fit output flange, new felt and steel washers.
7. Fit a new self-locking nut.







8. Position propeller shaft flange holding tool LRT-51-003 to output flange.
9. Restrain flange, tighten nut to 162 Nm (120 ft. lbs.).







10. Compress differential lock selector spring and fit to selector fork.
11. Locate fingers of selector fork in groove in dog clutch.
12. Fit differential lock selector shaft ensuring end of shaft is located in recess in rear of housing.
13. Rotate selector shaft until the two flats for the retaining clips are at right angles to the cover plate mating face.







14. Compress selector spring and fit retaining clips at each end of spring.

CAUTION: Ensure ends of spring are fully seated in recess in clips.







15. Fit differential lock detent ball and spring.
16. Apply Loctite 290 to threads of detent plug.
17. Fit and tighten detent plug then unscrew 2 full turns.







18. Ensure 'O' ring is correctly located on differential lock selector housing.
19. Fit differential lock selector assembly ensuring that selector finger is located in recess in differential lock selector shaft.
20. Apply Loctite 290 to threads of bolts.
21. Fit bolts and tighten to 25 Nm (18 ft. lbs.).
22. Operate differential lock selector lever and check that differential lock detent ball can be felt to positively engage and disengage with grooves in selector shaft; screw detent plug in or out until setting is correct.
23. Apply Hylomar PL32 sealant to threads of differential lock warning lamp switch, fit and tighten switch.

CAUTION: Do not allow sealant to contact switch plunger, do not tighten locknut or fit differential lock side cover until switch has been adjusted.







24. Up to serial no. 288709E: Apply grease to new high/low selector housing gasket, position gasket on front output housing.
25. From serial no. 288709E: Apply Hylosil RTV 102 sealant to mating flange of high/low selector housing.
26. Fit housing ensuring that high/low selector finger is located in recess in high/low selector shaft.
27. Fit 6 bolts and tighten to 25 Nm (18 ft. lbs.).

Intermediate gears







1. Insert a new collapsible spacer into intermediate gears, fit bearings into bearing tracks.







2. Wrap a suitable length of wire around intermediate gears and using assistance, lower gears into main casing ensuring that they are meshing with input and differential gears.

CAUTION: Do not remove wire at this stage.







3. Lubricate new 'O' rings with recommended oil and fit to intermediate shaft and main casing.







4. Raise intermediate gears until dummy shaft LRT-41-004 can be inserted from front output housing side of main casing.
5. Fit intermediate shaft, drift shaft into position whilst at the same time expelling dummy shaft LRT-41-004 .

CAUTION: Ensure 'O' ring is not displaced from main casing.

6. Remove wire from around intermediate gears.







7. Rotate intermediate shaft until retaining plate can be located on flat on shaft.
8. Apply Loctite 290 to threads of retaining plate bolt.
9. Fit bolt and tighten to 25 Nm (18 ft. lbs.).
10. Fit a new intermediate shaft nut.
11. Tighten intermediate shaft nut in small stages until all end-float is removed from intermediate gears.

CAUTION: Check end-float of intermediate gears between each stage, do not continue tightening nut after end-float is removed. Do not stake nut at this stage.

12. Set intermediate gear bearing pre-load - See Intermediate gear bearing pre-load.

Intermediate gear bearing pre-load
1. Select neutral.
2. Screw a suitable bolt into tapped hole in end of tool LRT-41-005.







3. Insert tool LRT-41-005 in end of mainshaft.
4. Using a suitable torque meter on tool LRT-41-005, check and record torque to turn mainshaft input gears.
5. Tighten the intermediate shaft nut in small stages checking the torque to turn the input gears until the mainshaft input gear torque to turn figure recorded in operation 4 has increased by 1.25 Nm (10 lbf.in).

CAUTION: Take great care not to overtighten nut as this will cause excessive bearing pre-load. If torque to turn figure is inadvertently exceeded, a new collapsible spacer must be fitted.

6. When torque to turn figure - intermediate gear bearing pre-load is correct, stake flange of intermediate shaft nut into recess in intermediate shaft.
7. Remove tool LRT-41-005.







NOTE: Discovery cover plate illustrated.

8. Up to serial no. 288709E: Fit and tighten 2 countersunk screws to secure mainshaft input gear bearing housing.
9. Remove 2 bolts used to temporarily secure mainshaft input gear bearing housing.
10. From serial no. 288709E: Remove mainshaft input gear bearing housing then apply Hylosil 2000 sealant to main casing mating face of bearing housing; position housing on main casing ensuring that reference marks are aligned. Fit and tighten 2 countersunk screws - if fitted.

If fitted

11. Lubricate a new 'O' ring with recommended oil and fit to oil feed plate.
12. Fit oil feed plate ensuring that word TOP is towards top of main casing and spigots are located in cut-outs.

NOTE: If a replacement input gear having a cross-drilled shaft is to be fitted, discard oil feed plate and 'O' ring.

All transfer boxes

13. Apply Hylosil RTV 102 sealant or position new, dry gasket to mating face of cover plate/power take-off cover. Position plate/cover on bearing housing ensuring that reference marks are aligned.
14. Position clip to stud nut.
15. Apply Loctite 290 to threads of bolts and stud nut.
16. Fit 5 bolts and stud nut and tighten by diagonal selection to 25 Nm (18 ft. lbs.).

NOTE: These bolts are threaded to head.

Bottom cover
1. Up to serial no. 288709E: Position new bottom cover gasket, dry on main casing.
2. From serial no. 288709E: Apply Hylosil RTV 102 sealant to mating face of bottom cover.







3. Fit bottom cover.
4. Apply Loctite 290 to threads of bottom cover securing bolts.
5. Fit bolts in positions shown and tighten by diagonal selection to 25 Nm (18 ft. lbs.).

High/low selector shaft detent







1. Fit detent ball and spring.
2. Apply Loctite 290 to threads of detent plug.
3. Fit and tighten plug then unscrew 2 full turns.
4. Operate high/low selector lever and check that detent ball can be felt to positively engage and disengage with grooves in selector shaft; screw plug in or out until setting is correct.

Interlock solenoid - if fitted







1. Position interlock solenoid in main casing.
2. Apply Hylosil RTV 102 to mating face of solenoid cover.
3. Fit solenoid cover and Belleville washer, fit bolts and tighten to 10 Nm (8 ft. lbs.).

Neutral warning lamp switch - if fitted - not Range Rover Classic







1. Apply Hylosil PL32 sealant to threads of switch.
2. Fit washer, fit and tighten switch.

Differential lock warning lamp switch - adjust







1. Move differential lock selector fork to differential locked position.
2. Connect a 12V test lamp and battery to differential lock switch.
3. Screw switch in until test lamp is illuminated then screw switch in a further 1/2 turn; tighten locknut.
4. Disengage differential lock, check that test lamp is extinguished.
5. Remove test lamp.
6. Up to serial no. 288709E: Apply grease to a new gasket and fit to differential lock side cover.
7. From serial no. 288709E: Apply Hylosil RTV 102 sealant to mating face of differential lock side cover.
8. Fit side cover, fit bolts and tighten to 25 Nm (18 ft. lbs.).

Transmission brake
1. Apply Hylosil RTV 102 sealant to mating face of rear output housing.







2. Position brake backplate on rear output housing ensuring that alignment marks are together.
3. Fit 4 bolts and tighten to 70 Nm (52 ft. lbs.).
4. Fit transmission brake drum, fit countersunk screw and tighten.

NOTE: Early transfer boxes - 2 screws are fitted.