LT230 rebuild

aaronmorris said:

I did my lt77 collar in the press. Does your press bed not drop right down?
No bell housing on mine so input shaft just sat through the bed and use a piece of metal pipe/scaffold bar to push it on.

Click to expand...

Aye it'll drop right down, it'll probably fit, just have measured up yet.

Wish I had some scaffold :lol:

Bennehboy said:

Just scratching my head about the best way to press the oil seal collar on...

Not sure if the gearbox will fit in my press stood on end, will have to check in a bit.

Read that it's not a good idea to hammer and drift it onto the shaft - could damage the bearings?

Click to expand...

lt77 does need pressing on, r380 will tap on with a suitable tube

Good to know, cheers James.

Well it fit into the press no problems:



Bit of improvisation due to not having a suitable bit of tube to hand:



Sorted:

Started to tear down the LT230 I'm refurbing....



PTO cover off:



Bearing carrier off, beartings are in great shape but I'm building the internals into a new case so am going to refresh everything:



Input gear out, no sign of blueing:



Sump cover off, bit mucky in there!:



Front output flange and housing off:



Intermediate gears out, they're in great shape, as are the bearings:



Sump plug and selector detent out:



Found this lump on the sump plug, but can't find any corresponding broken bits yet:



hi/lo selector housing off:



CDL selector housing off, and front flange off:



CDL switch out (to gain access to the bolt it obscures), one of the contacts is wobbly so I'll renew this:



Front output housing off:



Centre diff mechanism and selector out, again no sign of any broken bits, the diff has alignment marks on it so I figure this has been stripped down before:



One scrap case:



All the bits are going in the parts washer next before building into the new case... (old pic with the now used R380 rebuild items in)

Treated the R380 to a new turret gaitor:



Dismantled the LT230 front output housing and removed the bearing track.



Case bits don't want to seem to clean up much.

Pic to show how all the gears mesh, everything is in constant mesh, the selector on the diff carrier locks either the hi or lo gear to the splines on itself to select the appropriate gear:



Need some bigger internal circlip pliers, spent ages faffing with the pair I have.

My Halfords ones were spot on for LT230, just be persuasive!!

I've got a big pair of teng ones that work great on external clips, think I'll just get the internal version of those.

Just been thinking about how best to clean up the front & rear housings of this t-box, want to avoid wire brushing them because the existing finish looks good besides the oil/algae on them.

Would a solvent like acetone work well do you think? I've been using paraffin which works well for the oil based stuff but aint so great with the organics.

steam steam steam

and/or dishwasher

Mr Noisy said:

and/or dishwasher

Click to expand...

SWMBO would stab me in my sleep.

Not got a steam cleaner thingy.

Had to empty out the paraffin from the parts washer, it was really really really bloody skanky, there was 5mm of sludge/metal/crap/TOXIC WASTE in the bottom of it, nasty!

Chucked in another 12 litres of clean paraffin and cleaned up the bits I need from the donor t-box.

Seems to be cleaning better now, :clap2:

Going to get a brass brush on the front/rear housings then lacquer them up before finishing the build.

Did some cleaning in the parts washer - will need to wire brush some of the bits, they aint as shiny as I'd like



Pulled the bearings off the output shafts:



Popped the bearing retaining nut off the diff carrier, cheers to James for telling me to use a stilson and avoid splashing out on yet another tool (I'm a fool with money!). You can see the gold sheen on everything from the ground to paste brass thrust washers which live in the diff:



Pulled bearings off the diff carrier:





Ready for cleaning up:



Pulled the bearings off the input gear:

Yeah it's a bugger that retainer nut!

Having said that, a couple of cases I've done the nut has been loose!!

Mr Noisy said:

Yeah it's a bugger that retainer nut!

Having said that, a couple of cases I've done the nut has been loose!!

Click to expand...

thats quite common,and dont forget sun gear washers are sized to enable you to get correct load on diff gears ,.and diff case halves are marked so that they go back together correct

jamesmartin said:

thats quite common,and dont forget sun gear washers are sized to enable you to get correct load on diff gears ,.and diff case halves are marked so that they go back together correct

Click to expand...

Yeah you mentioned the sun gear washers before, the ashcrofts kit I have has 2 in but it's pot luck they'll be correct thickness I guess!

Mr Noisy said:

Yeah it's a bugger that retainer nut!

Having said that, a couple of cases I've done the nut has been loose!!

Click to expand...

Not surprised tbh.

Now that I've got this one sat in bits I can't help but think... hmm if I put 35" tyres on I could put a 1.4 gear set in it.... :lol::lol:

Bennehboy said:

Not surprised tbh.

Now that I've got this one sat in bits I can't help but think... hmm if I put 35" tyres on I could put a 1.4 gear set in it.... :lol::lol:

Click to expand...

Now we're talking

Did some more taking apart and cleaning....

Wire brushed the case bits, and all the other stuff cleaned in the parts washer, diff carrier split:



Gears look good:



And cleaned with the Ashcroft's HD cross pin test fitted:



T'other end:



Just got to pull the bearing races out of the intermediate gears and it can be reassembled in the new case.