LT230 Transfer Box stuck?

markdefender · Sep 13, 2011

Hello all,

I recently had a problem with the LT77 geabox on my Defender 110, I found a reconditioned box on eBay and I'm now in the process of changing it.

I have come up against a problem though. A friend advised me to split the transfer box and gearbox and mount them seperately. I therefore removed the 6 17mm bolts on the rear of the transfer box, then the 2 countersunk screws and slid out the gear.

However, now that I have got the transfer box reattached to the gearbox I can't get the gear back in? With the gear removed, the cogs inside will only move a few millimetres before clunking to a stop?

Any advice is most welcomed? Is it new transfer box time?

hooch · Sep 13, 2011

make sure you havn't mixed the 17mm bolts up as some are longer and can lock up the transfer box if put in the wrong holes.

lynall · Sep 13, 2011

Ifs its an early box like mine 200tdi/lt77 you have to fit the gear to the box then fit it in one go, the later ones you can remove the gear in situ.
I changed my gear by loosening all the bolts and baring the tfer box to one side but you have to be careful as you can damage the input seal.

Lynall

jamesmartin · Sep 13, 2011

1.222 transfer boxes have to be barred to one side because of hieght of high gear on intermediate gear cluster 1.410 dont but need to be free to turn as teeth are helical you need to turn gearbox shaft or put t/box in difflock and high and turn out put flange as fitting on intermediate gear cluste the gear at front is low and small middle gear is input driven rear gear is high on 1.222 boxes this gear is same height as middle gear, on 1.410 half a tooth smaller and 1.667 a wole tooth smaller hence ,1.2 been impossible to slide in /out unless space created by removing box or pulling to one side

markdefender · Sep 13, 2011

hooch said:
make sure you havn't mixed the 17mm bolts up as some are longer and can lock up the transfer box if put in the wrong holes.

Thank you Hooch that was fantastic advice - works perfectly now - gear back in and heading towards getting it back on the road.
THANK YOU!!

jamesmartin · Sep 13, 2011

for future referrence the one bolt that will jam transfer box up is the top one of two going into t/box from front

hooch · Sep 14, 2011

markdefender said:
Thank you Hooch that was fantastic advice - works perfectly now - gear back in and heading towards getting it back on the road.
THANK YOU!!

glad i could help. i learned the hard way and didnt get away with it.

Christopher24 · May 16, 2013

I all

I am new to this.

My landy 90 is stuck in diff lock position, my levers are in working order .

I had a look at the transfer case under the landy it looks like its jammed at the transfer case.

have tried rocking the landy will tapping it under the landy but its rock soled

What can be the problem or how can i get it out of diff lock....

Thanks in advance

LT230 Transfer Box stuck?

markdefender

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hooch

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lynall

Well-Known Member

jamesmartin

Well-Known Member

markdefender

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jamesmartin

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hooch

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Christopher24

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