LT230 rebuild

jamesmartin · Mar 31, 2014

count the teeth to be sure

Bennehboy · Mar 31, 2014

Ta, think I might have blagged a free 300tdi box minus extension housing...

aaronmorris · Mar 31, 2014

Bennehboy said:
Got naff all done today with it being Mothering Sunday...

Snook out to get a bling shot though

Oooh very nice

Bennehboy · Apr 2, 2014

Cracked on with the mainshaft disassembly...

Made a frankensteins monster puller using my bearing separator to pull the mainshaft support bearing off using first gear (picture is a bit crap):

Once the bearing was clear of its land I slid off the bearing, bush, needle roller and first gear:

Then the syncromesh hub assembly and baulk rings came off:

Now with that lot out of the way 3rd gear can be used to press off the pilot bearing:

Which can then be put to one side:

Closely followed by the spacer:

And then the syncromesh hub assembly and baulk rings (in reality 4th gear's baulk ring pops out when the mainshaft is decoupled from the pinion), you can see the wear here on the 4th gear baulk ring:

And wear on 3rd gears' baulk ring:

And finally 3rd gear slid off and everything lined up in order ready for bault rings & springs to be replaced with new, and all the needle rollers replaced as I rebuild the shaft.

Mainshaft rebuild next.

Mr Noisy · Apr 2, 2014

Jealous

turbominij · Apr 3, 2014

im loving this thread as its the exact jobs im about to undertake (transfer box at the weekend)

are you fitting hd support bearings to the R380? if so do you have any information on part numbers? adn any modifications needed?

Bennehboy · Apr 3, 2014

turbominij said:
im loving this thread as its the exact jobs im about to undertake (transfer box at the weekend)

are you fitting hd support bearings to the R380? if so do you have any information on part numbers? adn any modifications needed?

I read about the HD support bearings whilst flicking about on Ashcroft's website, I had a mail conversation with Dave Ashcroft who said they only supply the upgrade as part of a full rebuild because they have to machine the extension casing.

So, no I won't be upgrading.

I might mail again and ask if they are prepared to sell machined extension casings with the bearings in on an exchange basis though.

turbominij · Apr 3, 2014

though that might be the case as in the pic they do look a little bigger is a pitty have to stay stock then

Bennehboy said:
I might mail again and ask if they are prepared to sell machined extension casings with the bearings in on an exchange basis though.

that would be interesting

Bennehboy · Apr 3, 2014

I have a friend with a CNC machining center though....

turbominij · Apr 3, 2014

my dad has a big milling machine too

so if we no what bearings they are ???

Bennehboy · Apr 3, 2014

Ha, I don't expect Ashcroft's will be keen on handing that info out, but I'm going to try and find out.

Bennehboy · Apr 3, 2014

There's a bearing specialist down the road from me, I'll drop the stock ones in and get them to make some suggestions.

turbominij · Apr 3, 2014

good thinking from that and the info on the site with pics of bearings number of races should be able to work out what they are or be able to find something that will do the same job

Bennehboy · Apr 3, 2014

The other consideration to be made is that the plastic oil pick up ring sits against the main support bearing on a slightly large diameter bore - any replacement bearing would have to be smaller or the same size as that bore.

Here's the oil pickup in situ

And with it removed (casting is upside down):

Mr Noisy · Apr 3, 2014

They should be happy to do anything for money, why not.

Worth an ask.

I wouldn't build a box I knew I was keeping without exhausting all options.

turbominij · Apr 3, 2014

looks like there would be a good couple of mm increase in size possible

so long as the OD of the new bearing does not excede the oil pickup OD should work. once i have my box stripped il measure up unless u got a vernier to hand and can measure both on ur stripped box?

Bennehboy · Apr 3, 2014

turbominij said:
looks like there would be a good couple of mm increase in size possible

so long as the OD of the new bearing does not excede the oil pickup OD should work. once i have my box stripped il measure up unless u got a vernier to hand and can measure both on ur stripped box?

I've only got some crappy chinese digital calipers that won't get into the casting to measure the ID.

I could measure the bearing OD's (not very accurately!) but doubt that would give a good value for the interference fit.

turbominij · Apr 3, 2014

think we need to be bang on if its two tight it will cause the bearing to bind and fail (or crack casing) if its two loose it will flop about even minor issue and we will have carnage

Bennehboy · Apr 3, 2014

Called in at the local bearing factor...

So, they can supply a replacement for the mainshaft bearing no problem
N206 - 30x62x16mm - I need to check that the 16mm diameter is ok because on the RHP bearing only the center is that diameter...
Polycarbonate cage = 35 quid
Brass cage = 50 quid (a lot stronger!)

The layshaft bearing is the problem, it has a non standard ID of 16mm, they can however supply a bearing with a larger ID and a 'bearing ring' to reduce it to 16mm.

Looking at the Ashcrofts photos I suspect this is what they also do, because you can see a sleeve sat inside their HD layshaft inner.

turbominij · Apr 3, 2014

all very interesting whats the OD of the new main shalft bearing?

and yes now you mention it i also think thats what they have done explains the second (different coloured) ring

LT230 rebuild

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