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TRANSFER BOX - LT230SE OVERHAUL 41-55 Reassembly 1. Lubricate all components with recommended oil and lightly oil the differential bolt threads. 2. Secure rear half of differential carrier in a soft jawed vice. 3. Fit each planet gear to its respective cross shaft, fit new dished thrust washer to each 4. Fit cross shafts, planet gears and dished thrust washers in rear half of carrier.Ensure that 5. Fit retaining ring. gear from front half of carrier. Position gear in 7. Ensuring that assembly marks are aligned, fit both halves of carrier together. 8. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 Nm, 9. Insert the front output shaft into the front half of the carrier and check that the gears rotate 10. Fit output flange on to the splines of the output shaft, but do not fit flange nut at this stage. 11. Fit transmission brake drum to output flange and secure the drum using 2 nuts. 12. Secure a length of cord around the drum and attach one end of the cord to a spring balance. 13. Pull on the spring balance and note the load at which the brake drum starts to turn. Used 14. Compare the figure obtained with the following. l Used gears = 0.45 kg (1.0 lb) l New gears = 1.72 kg (3.8 lb) 15. If the load to turn figure is below the specified limits, proceed as follows. 16. Remove the front output shaft and brake drum. the differential carrier 18. Separate the differential carrier and remove the sun gear and thrust washer from the front half. 19. Select a thicker thrust washer from the range available. 5 different thrust washers are 20. Repeat steps 7 to 19 as necessary until the load to turn figure is as specified 21. When specified load to turn is obtained, proceed as follows. 22. Remove the front output shaft and brake drum. the differential carrier 24. Separate the differential carrier and remove the sun gear and thrust washer from the front |