Removal/Installation

ADAPTOR PLATE FOR REMOVING TRANSFER GEARBOX
The transfer gearbox is removed from underneath the vehicle. Using transmission hoist with an adaptor plate for securing the transfer gearbox to the hoist. The adaptor can be manufactured locally to the drawing above.

LT 230T:

WARNING: When using a transmission hoist it is essential to follow the hoist manufacturer's instructions.

REMOVAL
1. Site vehicle on a ramp [hoist].
2. Disconnect battery negative lead.
3. Remove fan cowl from radiator.
4. Remove transfer gear lever knob and gaiter.
5. Raise vehicle on ramp [hoist].





6. Drain oil and install plug, tighten to 30 Nm.
7. Detach heat shield at front exhaust pipe to manifold.
8. Disconnect electrical connector to oxygen sensors.





9. Remove catalytic converter assembly.
10. Remove chassis crossmember from under gearbox.
11. Remove heat shield from speedometer cable at transfer gearbox.
12. Remove clamp and disconnect speedometer cable from transfer gearbox.
- Tie cable to one side.
13. Mark for reassembly then disconnect propeller shaft to output flange, tie to one side.
14. Repeat on front propeller shaft to output flange.
15. Remove bolts retaining silencer front and rear securing brackets and tie silencer to one side.
16. Place four 30mm long spacers between top of hoist and adaptor plate, at securing points, and secure adaptor plate to hoist.
17. Remove four central bolts from transfer gearbox bottom cover, move hoist into position and secure adaptor plate to transfer gearbox.
- Adjust hoist to take weight of transfer gearbox.
19. Remove tie bar, transfer gearbox to main gearbox.
20. Remove nuts and bolts securing right transfer gearbox mounting bracket to chassis.
21. Repeat for left mounting bracket.
- Removal of these fixings will also free speedometer transducer bracket.
22. Remove right side mounting bracket to flexible mounting rubber.
23. Lower hoist until rear brake drum clears passenger footwell.
- Check engine does not crush any components while lowering.
24. Loosen park brake adjustment nut.
25. Remove park brake drum.
26. Remove park brake assembly complete from rear output flange.
27. Disconnect leads from transfer gearbox temperature sensor and differential lock warning light switch.
28. Remove banjo bolt from breather pipe, retrieve sealing washers and lay pipe aside.
29. Remove split [cotter] pin and washers securing differential lock to connecting rod and disconnect rod from lever.
30. Select low range transfer gearbox position.
31. Remove high/low rod lower lock nut and remove rod from yoke.
32. Position hoist jack channel under bell housing.
33. Using wooden block support the main gearbox and bell housing.
34. Remove upper and lower bolts securing transfer gearbox to main gearbox.
35. Install guide studs 1 8G 1425 to main gearbox and move transfer gearbox rearwards to detach.

INSTALLATION
36. Select "P" in main gearbox, with low range and differential lock selected in transfer gearbox.
37. Secure transfer gearbox to adaptor plate on lifting hoist.
38. Ensure joint faces of transfer and main gearboxes are clean and guide studs 1 8G 1425 are installed.
39. Raise hoist until transfer gearbox can be located over guide studs to main gearbox.
- At the same time locate high/low lower link to yoke.
40. Remove guide studs and secure transfer gearbox to main gearbox.
41. Complete installation by reversing removal procedure, noting the following important points.
42. After removal of adaptor plate from transfer gearbox, clean threads of four bottom cover bolts, coat threads with Loctite 290 and install together with spring washers.
- Tighten to 25 Nm.
43. Add correct grade of oil to transfer gearbox to oil level plug hole.
- Fill with up to 2.67 liters (5.70 US pints) of Dexron IID ATF.
44. Check main gearbox oil level.
45. Check operation of parking brake and adjust as necessary, refer to Brakes and Traction Control