LT230 rebuild

you can limit torque by using extension bars and drive size apadters ,the longer or thinner the bar the less torque applied

Sounds good that James

As it happens I was bolting the LT230 back together Wednesday night, adapted down to 3/8" and then with a 10" extension by the time it got to the socket it was actually quite gentle and you could pretty easily burst the gun to carefully nip the m8 bolts without trouble

So, with the stake nut off the lay shaft I could crack on with the dissassembly:

First job was to pull the damaged 5th lay gear off, and make sure the split washer doesn't go walkies!


Reverse gear then slides off the layshaft:


Next the collets and retaining ring come off the main shaft:


And then the mainshaft rear support bearing track needs pulling off - I used my bearing splitters to do this:


5th main gear and it's baulk ring can now come off the main shaft:


Only minor wear on the baulk ring:


Off comes the needler roller that 5th main sits atop:


Out with the grub screw holding the selector yoke, and tap the yoke off the selector shaft:



Now the circlip securing the 5th/Reverse selector hub needs to come off - wear eye protection!



The entire hub assembly and selector can now be slid off, make sure you keep the hub and ring aligned, you'll want to make sure they go back ion the same way. I had to tap the selector off with a punch and rubber mallet - I slaved a bolt into the centre plate and main casing to stop everything separating while I did this:




Now main reverse and it's baulk ring can come off:


I'm stacking everything in the same order as it comes off:


With main reverse off it's needle roller can be removed:


Then the bush and selectable spacer:



Now the detent springs and balls for the selector need to come out so the centre plate can be removed - be careful to catch the ball bearings, they don't like to play nicely:




Carefully lever the centre plate off and slide it over the main and layshaft - you'll need to support the shafts whilst doing this and be careful not to lose the bearing tracks from the centre plate, they can fall out:


First impressions are that the lay shaft and mainshaft gears are in really good condition


Next step is to remove the spool retainer so that the mainshaft and selectors can be slid out as one unit:



Mainshaft, layshaft, and pinion then simply slide out





Main case cleanup & mainshaft dissassembly next

Belting read mate

Selector shaft is quite warn from the detente ball bearings, and those are also looking quite pitted:


The 4th/3rd selector fork is really quite warn too:


I'll check what the one on the other box is like and swap it in if it's in better shape.

I'm thinking this reverse idler is scrap?


One in the other box is worse.

Looks chipped to me

Anyone got one going begging?

Only James Martin has the answer!

Degreased, jet washed and wire brushed the main case:



First coat of Zinc primer (3 in total):



First coat of matt black (still wet):



All rattle canned so no idea if it will be any good on a gearbox

3 coats of black going on then will do 3 of lacquer.

sweet

that'll last nicely and be much more washable

'pressed' the idler gear shaft out of the centre plate using a BFH & MAPP gas:




Set about cleaning the plate up ready for painting:

Looks good mate, And a good read
Not sure I'd have the bollocks to attempt to rebuild mine

Oh and where and how much was the milwaukee impact gun if you don't mind me asking

I bought it from a local stockist, lot of dosh, but dunno how I ever got on without one now TBH.

Just watched this Ashcrofts R380 rebuild video...

https://www.youtube.com/watch?v=vTyuszBpnC8

Lots of BFH use, no press involved at any stage, didn't see any endfloat checks at all... But then the video chops about so they could have left it out.

Bennehboy said:

Just watched this Ashcrofts R380 rebuild video...

https://www.youtube.com/watch?v=vTyuszBpnC8

Lots of BFH use, no press involved at any stage, didn't see any endfloat checks at all... But then the video chops about so they could have left it out.

Click to expand...

some leave endfloat ,ive found none is better , you dry build box with rear bearing plate on a suitable stand to allow shafts to poke through unhindered ,fit lay shaft and main shaft with input shaft ,then dry fit case and secure with 4 bolts then fit front bearing cover ,you can then check for end float or too much preload by feel if ok you can the rebuild with selector shaft and loctite all bearing races and shims into cover and plate ,it stops bearing races spinning case, usually during clutching or power changes

The spare bellhousing I have seems to work as a nice stand

Got naff all done today with it being Mothering Sunday...

Snook out to get a bling shot though

Instantly looks fixed!

Much better to put the extra effort in

Anyone know if the reverse idler gear from a 300tdi box will fit OK?

I'm assuming it will, but notice that at some point LR superceded the idler gear part no from FTC2725 to TUB102000 - just wondered if I need care about any differences?