LT230 rebuild parts and advice

aaronmorris · Sep 23, 2014

So a friend has asked me if I want to rebuild a transfer box for him.
I'd like to take it on as it's something I'd like to try, But still slightly dubious

I have read the manual and it seems relatively straight forward.
But am I under Complicating matters?
I have general tools, Bearing pullers for disassembly and a press for reassembly which should help. Anything else I may need?

I started putting a list of parts together anyway.
Have I missed anything? Or even buying something I don't need.
Or do I buy a complete kit from ashcroft or the like.
advice appreciated

2 x FRC5564
2 x FRC7810
2 x STC1130
1 x 606474
1 x FRC7871
1 X FRC7437
1 X UYH500020
1 X RHB500030
1 X STC3433
1 X STC3432
4 X FRC6968
1 X RTC3890

jamesmartin · Sep 23, 2014

you can reuse lock plate and nut for intermediate shaft and rear flange seldom needs changing ,fronts are often worn were seal runs, you want orings for intermediate shaft frc7439 and frc8292

aaronmorris · Sep 23, 2014

Cheers James, That makes sense, If I do it I'll be using my spare box to save having his off the road and I know the front flange is knackered. But as you say the rear one is in pretty good condition.

aaronmorris · Sep 23, 2014

On another note, What brand parts would you suggest?
I assume timken/skf for bearings.
But what about thrust washers etc?

jamesmartin · Sep 23, 2014

timken for the tapers ,fag or skf would do , i fit genuine if you can , the after market can often be too thick ,though your diff should have no play and be slightly notchy to turn

aaronmorris · Sep 23, 2014

jamesmartin said:
timken for the tapers ,fag or skf would do , i fit genuine if you can , the after market can often be too thick ,though your diff should have no play and be slightly notchy to turn

Cool, Cheers again James. Glad you told me that last bit as I'd have been wondering what I'd done wrong

aaronmorris · Sep 24, 2014

Well decided to just give it a bash, Not got much to loose really.
So got the box stripped this afternoon, Quite enjoyed it actually. Nice to see how it works. But then I am a bit sad like that

Ordered the bits this morning. Was hoping he would do it

Although it did mean I could order myself some bits and bobs. (Head, tail and carrier bearings for a diff) As that's one of the other jobs I need to tackle. (I'll try a spare diff first)
But I'll start another thread on that when the time comes

Anyway, Now the boring task of cleaning everything up

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jamesmartin · Sep 24, 2014

its not sad wanting to see how stuff works ,when you come to split the center diff you will see there is stamped numbers or letters on both halves so you can put them back together correct

aaronmorris · Sep 24, 2014

jamesmartin said:
its not sad wanting to see how stuff works ,when you come to split the center diff you will see there is stamped numbers or letters on both halves so you can put them back together correct

No, I agree James, I enjoy seeing how stuff works, It's everyone else who tells me I'm a sad c*nt and why would I bother.
But then I guess that's why they pay people to do everything for them.
I've also got a lt77 that needs a main shaft (Due to spline wear) If I dare take it on.

It's not ideal trying to do stuff you've never been shown, But the manuals are pretty good and theirs plenty of advice from you and others on here if need be.

Ah, Never new that about the center diff. I was going to make my own markings. But no need now

greyhair · Sep 25, 2014

I think a lot of people are put off if you need special tools
and the fact that it can be exspensive to buy them.
so yes its easier to get someone to do it.
As for you beeing a sad c*** as you put it, i dont think so mate
whats wrong with learning your craft, you can do everything else so why not

I took the easy way out and sent my gear box to a very nice chap

)
as i did not fancy stripping it myself

aaronmorris · Sep 25, 2014

greyhair said:
I think a lot of people are put off if you need special tools
and the fact that it can be exspensive to buy them.
so yes its easier to get someone to do it.
As for you beeing a sad c*** as you put it, i dont think so mate
whats wrong with learning your craft, you can do everything else so why not

I took the easy way out and sent my gear box to a very nice chap )
as i did not fancy stripping it myself

Yeah, I agree re the special tools, But I've got most hand tools, Bearing pullers and a press which is a big chunk of stuff.
So if I have to buy odd bits and bobs then as long as they're not hideously expensive I don't mind, Because I'm only young and as far as I'm concerned they should pay for them selves or save me the money in my life time.

But I can see exactly why people would pay someone to do it.
I just enjoy doing it, Seeing how stuff works and a challenge to what I've done before.
I said it yesterday and it's not ideal doing everything from a manual as stuff could possibly be misinterpreted but they're pretty good to be honest.
I'd love someone to show me how to do it properly but everyone I know wont even touch gearboxes or the like.
Oh, And yeah, I don't think I'm a sad c*nt either bud, It's just what everyone else tells me, i.e non lr owners.

mick the builder · Sep 25, 2014

greyhair said:
I think a lot of people are put off if you need special tools
and the fact that it can be exspensive to buy them.
so yes its easier to get someone to do it.
As for you beeing a sad c*** as you put it, i dont think so mate
whats wrong with learning your craft, you can do everything else so why not

I took the easy way out and sent my gear box to a very nice chap )
as i did not fancy stripping it myself

+ 1
Im going to send my g.box to a very nice chap also. I wonder if its the same chap?

aaronmorris · Sep 25, 2014

mick the builder said:
+ 1
Im going to send my g.box to a very nice chap also. I wonder if its the same chap?

Most probably if it's the nice chap off here

Bennehboy · Sep 25, 2014

Aaron shout if you need any bits, got loads of extra ****e here.

aaronmorris · Sep 25, 2014

Bennehboy said:
Aaron shout if you need any bits, got loads of extra ****e here.

Cheers for the offer Ben

Don't think I need anything up to press, But you never know.

aaronmorris · Sep 25, 2014

Cleaned everything up for reassembly today, They're far from perfect but much better than they was. Just used what I had.
Output housings were the worst as they've got loads of nooks and crannies.
Will get a final clean and blow out with brake cleaner just before assembly.
I'm hoping the bits turn up tomorrow so I can build it back up over the weekend, But I think that's wishful thinking.
Probably be Monday when the bits turn up.

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aaronmorris · Sep 28, 2014

Removed the rest of the bearings this morning, Does anyone know if this bearing on top of the centre diff meant to be a press fit?
I removed the lock nut fully expecting to have to use a puller and was surprised when it pulled off in my hand

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On another note, I think I've decided to give the lt77 a bash, So this scruffy looking thing may be my next project. Should be interesting

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jamesmartin · Sep 28, 2014

bearing should be a tap on fit if its loose loctite the new one

aaronmorris · Sep 28, 2014

jamesmartin said:
bearing should be a tap on fit if its loose loctite the new one

Cheers James, The one I've removed slides on and off easily, I'll see what the new ones like and loctite if necessary.

Another question

When you build transfer boxes James to you use gaskets or silicone?

jamesmartin · Sep 28, 2014

if bearing is loose it will spin under certain conditions like setting off and gear changes ,wearing diff tube,you need to use gasket for 200 tdi and previous and silicone for 300 tdi onwards ,because gaskets are 12 thou ish thick and would alter the shimming of bearings

LT230 rebuild parts and advice

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