Spitting output housing from Transferbox

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Marney96

Member
Posts
18
Location
Staffordshire
Hi,
My front output shaft bearing is shagged on my Lt230 Defender (presumably by previous owner running big tyres and lift kit, now removed) I’m trying to pull the shaft out of the box but it won’t budge at all I’ve tried pullers, leverage, hammer and leverage, slide hammer to name a few. I’m starting to realise that I’m probably going to have to split the output housing from the main box and was wondering if this can be done in situ? To me it looks like a few 10mm bolts and a bolt that holds it do the chassis? Any advice would be greatly appreciated 😀.
 

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Don't think it's that simple .... there is a circlip on the inside and the shaft is inside the diff itself.

It's not 'that hard' to take the complete LT230 out.
Use a jack of some description as although it's not that heavy (around 56kg's) it's awkward.
 
Thanks for the advice, do you know if I’d need to drain the gearbox to drop the T Box? I’ve seen various videos online of people just removing the whole shaft with a slide hammer.
 
Marney96 said:
I’ve seen various videos online of people just removing the whole shaft with a slide hammer.
Click to expand...

So you have a drive flange bolted onto the end of the shaft to quite a torque (140NM ? - can't remember), so what do you think that torque is applied against ?

In your scenario, why doesn't it just pull the bearing straight out of the housing ?
It must be bigger on the inside no ?

The gearbox is sealed so no need to drain.
 
I am sure I have seen in Land Rover paperwork somewhere that you pull that bearing outwards leaving the shaft in situ
 
To remove the bearing the front housing has to come off unless you are lucky enough to get a grip on the inner race having removed circlip be able to pull it out. The shaft can not be removed from the front.
Disconnect high/low lever, and diff lock lever.
The 6 bolts holding high/low cross shaft on top of box have to be removed and shaft lifted out.
The bolts around the housing have to come out along with the diff lock lamp switch to get to one bolt.
Housing comes off leaving shaft in place exposing the center diff.
 
Heres a few pages from the LT230 manual (which can be found free online) which may help explain it.

Shaft out the back (after removing housing)
Bearing out the front (after remove circlip)

J
 

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  • LT230 2.pdf
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tottot said:
It does come out the front, problem is it is tight in there. Manual mentions whacking it out with a mallet.
Click to expand...

Never done it, But.
The manual mentions removing the housing and using a mallet to remove shaft.
Then it goes on to say remove bearing.

Now if the shaft actual fits through the bearing hole, after you have removed all the bits that would hang it up 🤔, you would have to whack it pretty hard to remove the outer race of the bearing.

J
 
Take the flange off, remove the circlip and pull the shaft out (with the bearing). You might need a slide hammer to pull it out, I used a metal bar and a hammer to knock it out. I don't remember it being particularly difficult or tight to get out.
Remove bearing from shaft, fit the new one to the shaft and tap it back in.
You will need to bolt something to the end of the shaft to pull it out or knock it out.
Hope that makes sense.
 
I have just been rebuilding an Lt 230, it had sat a long time but not done many miles so mostly clean up, seals and gaskets and new cross drilled input gear. I removed front housing to have a good look into the center diff.
Which way to get out just depends on how tight the bearing is in the housing.
 
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