LT230 rebuild

jamesmartin · Jan 9, 2015

presume youve got new thrust washers

Bennehboy · Jan 9, 2015

jamesmartin said:
presume youve got new thrust washers

yup - like I say was just testing it, hence why they're not on.

Bennehboy · Jan 11, 2015

What's the best way to get the bearing races out of the intermediate gears? I can probably brute force them out but wondered what others do?

Tried so far:

Blind bearing puller on slide hammer - no joy
Large drift and BFH from the reverse side - no joy

Was going to get some heat on the gears next but not sure if that's a good idea...
And was going to try my 20ton press to push them out from the back with the blind bearing puller pushing...

They seem to be really well in there!

So when it comes to fitting the new ones, hot air gun on the gear and races in the freezer? Not so sure how to press these in with the edges being so thin.

jamesmartin · Jan 11, 2015

long drift from the rear side best to place drift in circlip gap first then move to opposite side , use old race to press new races in

Bennehboy · Jan 11, 2015

Thought so, ta.

Will warm up the gears a bit to see if it helps the races come out.

Bennehboy · Jan 11, 2015

Little beat of heat into the gear and the bearings drifted out no bother

Bennehboy · Jan 12, 2015

Think I need to add another tool to the chest...

LT230 overhaul manual says I have to set up the diff preload using a spring balance and checking the load to turn?

Is there an easier way? (endfloat?)

Bennehboy · Jan 12, 2015

Bit cold for it but painting of the 380 is underway, don't want the case to rust up.

Mr Noisy · Jan 12, 2015

That's the way it says to do it, but of course you could easily do it by feel and get most of the way

Bennehboy · Jan 12, 2015

Mr Noisy said:
That's the way it says to do it, but of course you could easily do it by feel and get most of the way

How did you do yours?

Bennehboy · Jan 12, 2015

Ignore that, you put an ATB in...

jamesmartin · Jan 12, 2015

Bennehboy said:
Think I need to add another tool to the chest...

LT230 overhaul manual says I have to set up the diff preload using a spring balance and checking the load to turn?

Is there an easier way? (endfloat?)

i have one of these as it dose input ,diff and intermediate gears , though you can do it by feel ,maybe not accurate but non of lrs are anyhow ,they should be preloaded just enough so they wont free wheel ,input you set to 10-15 inch lbs, then put hi/lo in neutral fit intermediate ,measure drag ie input plus a little from loose intermediate then tighten the nut till intermediate has added another 10-15 inch lbs to input reading, i use an old mainshaft and output shaft cut and a socket welded on

Bennehboy · Jan 12, 2015

D2 intermediate doesn't use a crushable spacer, so not sure how it would be possible to do preload.

jamesmartin · Jan 12, 2015

very true ,but instead of tightening nut you select the correct spacer

Bennehboy · Jan 13, 2015

Reckon something like this would work?

https://www.machinemart.co.uk/shop/...ht735-digital-luggage-scale?da=1&TC=SRC-scale

Mr Noisy · Jan 14, 2015

yes mate spring balance just like that

Bennehboy · Mar 5, 2015

Quick update... done bugger all while the weather has been cold/****.

Will get cracked on with completing the tbox when things pick up.

Bennehboy · Jul 7, 2015

So given that the chassis swap is happening next week I thought I'd better crack on and finish rebuilding my spare transfer box to swap in...

Last time I worked on it I'd fully dismantled everything and cleaned it all up ready for reassembly.

So first thing was to fit the HD cross pin and new thrust washers - I'm not bothering checking the diff preload because I'm using same make of bearings to refit it all (and I'm lazy!)... I did hand test the preload and there's a reasonable amount of drag/force required to get it turning.

Next the carrier is put back together and the bolts torqued up to 70nm, all the gears and selector hub is put back on, bearings pressed on either end using the old bearing centers as pushers, and a new bearing retaining nut fitted and staked

Then the case starts to get some prep, filler and drain plugs fitted, oil temp sender blank fitted (I'll be putting the sender in here from my existing box later)

Next job will be to press bearing tracks into the main case and front output housing to fit the diff carrier....

aaronmorris · Jul 7, 2015

Nice work Ben, everythings looking nice clean and shiny

Could have borrowed my torqometer doo-da to check centre diff had I known.

Bennehboy · Jul 7, 2015

aaronmorris said:
Nice work Ben, everythings looking nice clean and shiny
Could have borrowed my torqometer doo-da to check centre diff had I known.

I've got a scale I could've used but tbh I just went with what feels right as per JM's previous post.

LT230 rebuild

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Coming in your ears.

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Coming in your ears.

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Head's a shed

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