LT230 rebuild

This site contains affiliate links for which LandyZone may be compensated if you make a purchase.
Bennehboy said:
Ooh Sykes Pickavant, posh bugger ;)

I'll see how I get on and give you a shout, Donny's a bit closer than Louth :D
Click to expand...

'tis a bit posh for me :p Bought it when I did the lt77.
And yes just a bit closer, I went to the very mans place the other day and took about an hour and half.
The offers their and you know where I am if it's needed anyway.
 
This gearbox is having a laugh...

Bought another puller, still cheapo but with stronger legs, this is what happened before one of the legs finally gave way (used a shed load of MAPP on the collar too):
IMG_20141223_121225.jpg


Crackers :/
 
Where there's a will there's a way, pried the front case off whilst tapping the output shaft bearing outer race in with a suitable drift.

Going to cut the end off the shaft off with a slitting disk on the grinder, job jobbed.

IMG_20141223_131645.jpg


All the gearsets and layshaft will still be salvageable, seem to have the makings of a fine collection! :D
 
Dremel to the rescue...

IMG_20141223_134530.jpg


Getting the 5th & reverse of the main and layshafts is a doddle after that:

IMG_20141223_140219.jpg


The collar that sits under the mainshaft reverse gear was close to being friction welded to the shaft, had to heat it up to get it off - so shaft is probably scrap anyway :D
 
Stripped it down completely ready for painting...

Gears & bearings are all in great shape - kept all the shims for when I reassemble with the new innards:
IMG_20141224_164954.jpg


The centre plate (that I'm so good at breaking!) - reverse idler NOT being removed!
IMG_20141224_165009.jpg


It's no wonder Phil had crunching gears, all the synchros are well and truly goosed:
IMG_20141224_165318.jpg


4th gear:
IMG_20141224_165540.jpg


Ready to chuck in my dissasembled gearbox pile:
IMG_20141224_171608.jpg


Bit of wire brushing then these can get painted up:
IMG_20141224_171616.jpg
 
Cleaned up the main case, and decided to test fit the shafts to check bearing preload.

IMG_20141229_140539.jpg


I think the layshaft seems OK, there's drag (maybe slightly too much?) with the same shim from the donor case, see video here -> R380 layshaft preload - YouTube

Mainshaft doesnt have enough preload, this is with the thickest shim, 2.3mm (other 2 shims I have are 2.1mm) -> http://www.youtube.com/watch?v=yXJkYEOykcQ?list=UUXNbwoJBaP-xZGcQF4L0Pew

Hoping JamesMartin will know the answer about whether I can get a thicker shim - I suppose I need a thinner spacer for the other side of the bearing too?

EDIT...

Just fired up Microcat and there seem to be a shed load of spacer sizes available:

FTC3761 - 2.290/2.265mm (dunno why there are 2 thicknesses listed, is this the tolerance?), this is probably the thicker one I have but I don't trust the chinese knock off caliper I have

The shims go up in 0.05mm steps from there all the way to 2.940mm

At 10 quid per shim I don't want to 'just take a punt'!
 
Last edited:
OK so here's some screenshot from microcat, first is the shim selections around and above the thickness of the one I have:

mainshaft_shim.jpg



And these are the corresponding shims for the 5th/reverse side of the bearing, so whichever one I get above I'll probably need to thin down the 5th/rev side by the same difference:

4-5-shim.jpg


Any science behind choosing them?
 
you can measure shim size needed by building without a shim or a too small shim then measure endfloat with a dti , but from vids they dont look bad as long as m/s has no endfloat ,l/s isnt too heavily loaded shims come in 2 thou variants ,so 2 thou of l/s may be too loose if your changing baulk rings box has 4 ftc3584 and 2 ftc5018 (input shaft and 5th gear
 
jamesmartin said:
you can measure shim size needed by building without a shim or a too small shim then measure endfloat with a dti , but from vids they dont look bad as long as m/s has no endfloat ,l/s isnt too heavily loaded shims come in 2 thou variants ,so 2 thou of l/s may be too loose if your changing baulk rings box has 4 ftc3584 and 2 ftc5018 (input shaft and 5th gear
Click to expand...

Aye it's got all new baulk rings on. Can't believe I didn't think about using a DTI, doh!

I'll measure it up tomorrow, cheers.
 
You must log in or register to reply here.

Similar threads

usna87
LT230 grinding noise?
Replies
12
Views
1K
usna87
usna87
MollyNomad
IRD REBUILD KIT BEARING CONUNDRUM!
Replies
8
Views
429
MollyNomad
MollyNomad
tankduck
Stupid LT230 mistake!
Replies
8
Views
1K
lynall
L
A
Disco 1 LOUD CLICKING NOISE POSSIBLY FROM LT230
2
Replies
24
Views
4K
D1Nut
D1Nut
D
Tappets failed
Replies
7
Views
2K
Bobsticle
Bobsticle
Back
Top