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Poorly LT230


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22 hours ago, western said:

Transfer box off, intermediate shaft & gears out, bearings removed, No big damage to transfer case, 

Only damage is the rear bearing which has broken up, front bearing is in one piece but had roller damage, 

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smooth the sharp edges off with some 1000grit sandpaper and they good to go again, I say put them back in....they didn't seem to be making much noise anyway 🤷‍♂️

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New intermediate shaft, bearings, spacer tube & the gears set are fitted, waiting for a spring balance delivery tomorrow so I can set the preload correctly which will partly collapse the spacer tube then the shaft nut can be staked in place, 

I chopped the head & tail off the old intermediate shaft to make a dummy shaft to assist with fitting gears, bearings & spacer, the tapped the new shaft through to secure them all in the casing. 

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Ralph, unless you've got a jack here's a method I found quite useful when fitting my transfer box on my own.

I put two ladders outside each front door ratchet strapped to the chassis. I then placed an old fence post (4x4") through the windows supported on the ladders. That way I could put a small pulley block (about £10 from Amazon) on the post and tied off to a seat base in the back - was invaluable in lifting it and holding it in place whilst I went about shoving it into place.

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I'm waiting on 2 deliveries one is oil seals for the main shaft on main gearbox & transfer box, other is a spring balance so I can set the intermediate gear bearing preload, 

I haven't got space for ladders like that Ed, I do have a extra pair of hands available, so we can jack TB up, with a strap around it from above, I have 2 long studs in main gearbox rear face ready to help guide TB in to place. 

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Really - you mean you can't open the doors? Admittedly mine were only two short ladders (each about 8ft tall). Perhaps I wasn't clear - they were vertical alongside the body - not sticking out so didn't even stick proud of the wing mirrors. Hence why I strapped them to the chassis leg underneath.

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if you want to replace both the front and rear seal of your main gearbox, take care of the gasket on the front. I found, that they often have different thickness and that is interesting for endfloat of the main shaft

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53 minutes ago, Ed Poore said:

Really - you mean you can't open the doors? Admittedly mine were only two short ladders (each about 8ft tall). Perhaps I wasn't clear - they were vertical alongside the body - not sticking out so didn't even stick proud of the wing mirrors. Hence why I strapped them to the chassis leg underneath.

Ah, I thought you meant they were lengthways from the doors, anyway I haven't got a 2 part ladder to try it. We will get it in, I' did it back in 2008 when this LT230 was fitted

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53 minutes ago, Sigi_H said:

if you want to replace both the front and rear seal of your main gearbox, take care of the gasket on the front. I found, that they often have different thickness and that is interesting for endfloat of the main shaft

It's just the mainshaft rear seal on R380 & the front seal on LT230, where the 2 meet together, they are probably ok, but as its apart, its easy o swap for new seals, then I don't have to touch them again.

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Well got the above done, the torque at the nut is as mentioned in the text ^^^^^^ so the big sump is refitted, I can't move forward as I'm waiting on the 2 oil seals to be delivered tomorrow, then TB can be lifted & bolted back in to 110. 

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