Post by Admin on Jun 19, 2014 6:34:44 GMT
LT95 Transfer Case High ratio Gear Set Project 0.9962
Parts pages 30-70...77
Repair manual, Gearbox section 37
Actual Parts ordered from LRSeries.com
1 off FRC4050 with 45 teeth. intermediate Gear
1 off FRC 4032 with 25 teeth. Output Gear
1 off 532323 Intermediate shaft O ring.
1 off FRC3507 intermediate shaft LRSeries Turned out to be OK
3 off 594290 Needle Roller Bearing LRSeries
4 off 591896 Thrust Washer
1 off 606754 LT95 Gasket set
not ordered, items intended to be used out of 606754(above)
1 off FRC7104 (571948) Bottom Cover Gasket
1 off 571940 Speedo Housing Gasket
1 off top centre diff cover gasket
Poss requirement for replacement pear shaped washer the thickness of which can only be determined during the rebuild parts page 30-70 item 6, 591891 ..897,898,899
There has been talk of using Needle roller thrust bearings to replace the thrust washers (591896) in the event of the Gearbox overheating, may cause a secondary problem possibly greater than that which cause the primary problem of the box overheating/ loos of oil / contamination etc..
Special tools
8x1.25 studding to remove intermdiate shaft , its worst case, may also need washers sockets and small piece of angle with 8mm hole to bridge access hole as make-shift extractor.
Roller bearings push onto a new shaft.
You may need Gear Puller This is to get the gear off of the Centre diff section. (2 or 3 legged puller) check distance to pull and size of puller available. I didnt need it. I dont know anyone else who has either.
Small steel disk size of 50P to cover the holle in the differential stub shaft end whilst using the gear puller. Counter sink in middle of plate to align gear puller. Again I didint need it.
Small bar and longish flat screwdriver, hacksaw blades to poke cogs etc into line whilst feeding shaft back in.
Lead lamp that doesnt ming gears repeatedly falling on it.
Put Transfer case into nuetral.
Run engine put difflock on.
Chock the wheels, handbrake becomes defective.
Drain the Transfer oil.When you drain the oil you will see shiny material in the oil. Usually its from the faces of the thrudt washers - dont be alarmed.
Remove the Lower Transfer access panel and or winch drive
Disconnect the Rear Propshaft at the Transmission Brake.
Disconnect the Transmission Brake Linkage at the Speedo Drive Housing.
Disconnect the Speedo Cable at the housing end.
Remove the rear Housing Bolts, then withdraw the rear housing. Not one on front face pointing backwards.
The Intermediate Shaft is held in behind this. Screw studding into shaft and withdraw - encourage - dropping out thrust washers and gears one by one as the shaft exits.Note order and one washer inside another and near start and orientations. Then Withdraw the Centre Differential Stub Shaft asy. Center diff Front taper roller may stayin housing then droop out on floor.
Remove the High Speed Gear from the Differential Stub Shaft, note orientaion it has an offset. May need Gear Puller. I didnt.
Refit the Differential Assembly
Refit Intermediate shaft / gears / bearings . As per manual
Check and adjust end float as ness. using alternative pear shaped washer. End Float 9-14 thou. NB getting this right does alot to reduce the clonking in gear changes.
Refit the Rear Housing , speedo cable, Transmission Brake Linkage, Rear Prop Shaft, access panel or winch drive.
Refill the with oil. Check Transfer box is in nuetral. Start and take diff lock off. Stop engine.
Try high ratio. Jack a rear wheel, test diff lock on and off.
Test drive and check box temperature when returning .
Rear Diff refurbishment Project
> >>> 607181 Outer Diff Pinion Bearing - Sailsbury Axles
> >>> 607180 Inside Pinion Bearing - 4-Pin - Defender
> >>> 607183 Pinion Oil Seal Gasket
> >>> RTC1010 Use AAU3381
> >>> AAU3381 Use AEU2515
> >>> AEU2515 Outer Diff Pinion Oil Seal - Sailsbury
> >>> Axles - Defender to WA159806/Series/101
> >>> AEU2515G Sailsbury Pinion Oil Seal (Leather) - Defender to
> >>> WA159806/Series/101 ? 2.53
> >>> 607197 Crush Spacer - Pinion - 4-Pin - Defender
> >>> 607177 Shim - Diff Pinion - 0.003in
> >>> 607178 Shim - Diff Pinion - 0.005in
> >>> 607179 Shim - Diff Pinion - 0.010in
Other useful parts in area
Front output shaft
217325 Front output Ball Bering SKF RLS10 or LJ 1 1/4C3
571175 Front Output Seal ** see update below
571177 Front Mud Shield
Rear Output Shaft
GRB203 Rear output ball. bearing >>> use STC1130 Timken 6207
594029 Rear output Seal ** see update below
Both seals now replaced with Viton Double lip seals..
1.75x2.75x0.43 inch Viton Rubber Double Lip Rotary Shaft Oil Seal with Spring
45x72x10mm TC / R23 Double Lip Viton Rubber Metric Shaft Oil Seal with Spring
Centre diff
606473 front taper bearing >>>use FRC7871 Timken 32011X
606474 Rear taper bearing Timken JLM 104948/ JLM 104910
608142 LT95 Replacement Pinion Set inc copper washers.
HD230 Pin Heavy Duty Centre Diff Cross Pin (Ashcroft Transmissions)
606754 LT95 Gasket Set Bought previously.
Rear Diff refurbishment Project
> >>> 607181 Outer Diff Pinion Bearing - Sailsbury Axles
> >>> 607180 Inside Pinion Bearing - 4-Pin - Defender
> >>> 607183 Pinion Oil Seal Gasket
> >>> RTC1010 Use AAU3381
> >>> AAU3381 Use AEU2515
> >>> AEU2515 Outer Diff Pinion Oil Seal - Sailsbury
> >>> Axles - Defender to WA159806/Series/101
> >>> AEU2515G Sailsbury Pinion Oil Seal (Leather) - Defender to
> >>> WA159806/Series/101 ? 2.53
> >>> 607197 Crush Spacer - Pinion - 4-Pin - Defender
> >>> 607177 Shim - Diff Pinion - 0.003in
> >>> 607178 Shim - Diff Pinion - 0.005in
> >>> 607179 Shim - Diff Pinion - 0.010in
Parts pages 30-70...77
Repair manual, Gearbox section 37
Actual Parts ordered from LRSeries.com
1 off FRC4050 with 45 teeth. intermediate Gear
1 off FRC 4032 with 25 teeth. Output Gear
1 off 532323 Intermediate shaft O ring.
1 off FRC3507 intermediate shaft LRSeries Turned out to be OK
3 off 594290 Needle Roller Bearing LRSeries
4 off 591896 Thrust Washer
1 off 606754 LT95 Gasket set
not ordered, items intended to be used out of 606754(above)
1 off FRC7104 (571948) Bottom Cover Gasket
1 off 571940 Speedo Housing Gasket
1 off top centre diff cover gasket
Poss requirement for replacement pear shaped washer the thickness of which can only be determined during the rebuild parts page 30-70 item 6, 591891 ..897,898,899
There has been talk of using Needle roller thrust bearings to replace the thrust washers (591896) in the event of the Gearbox overheating, may cause a secondary problem possibly greater than that which cause the primary problem of the box overheating/ loos of oil / contamination etc..
Special tools
8x1.25 studding to remove intermdiate shaft , its worst case, may also need washers sockets and small piece of angle with 8mm hole to bridge access hole as make-shift extractor.
Roller bearings push onto a new shaft.
You may need Gear Puller This is to get the gear off of the Centre diff section. (2 or 3 legged puller) check distance to pull and size of puller available. I didnt need it. I dont know anyone else who has either.
Small steel disk size of 50P to cover the holle in the differential stub shaft end whilst using the gear puller. Counter sink in middle of plate to align gear puller. Again I didint need it.
Small bar and longish flat screwdriver, hacksaw blades to poke cogs etc into line whilst feeding shaft back in.
Lead lamp that doesnt ming gears repeatedly falling on it.
Put Transfer case into nuetral.
Run engine put difflock on.
Chock the wheels, handbrake becomes defective.
Drain the Transfer oil.When you drain the oil you will see shiny material in the oil. Usually its from the faces of the thrudt washers - dont be alarmed.
Remove the Lower Transfer access panel and or winch drive
Disconnect the Rear Propshaft at the Transmission Brake.
Disconnect the Transmission Brake Linkage at the Speedo Drive Housing.
Disconnect the Speedo Cable at the housing end.
Remove the rear Housing Bolts, then withdraw the rear housing. Not one on front face pointing backwards.
The Intermediate Shaft is held in behind this. Screw studding into shaft and withdraw - encourage - dropping out thrust washers and gears one by one as the shaft exits.Note order and one washer inside another and near start and orientations. Then Withdraw the Centre Differential Stub Shaft asy. Center diff Front taper roller may stayin housing then droop out on floor.
Remove the High Speed Gear from the Differential Stub Shaft, note orientaion it has an offset. May need Gear Puller. I didnt.
Refit the Differential Assembly
Refit Intermediate shaft / gears / bearings . As per manual
Check and adjust end float as ness. using alternative pear shaped washer. End Float 9-14 thou. NB getting this right does alot to reduce the clonking in gear changes.
Refit the Rear Housing , speedo cable, Transmission Brake Linkage, Rear Prop Shaft, access panel or winch drive.
Refill the with oil. Check Transfer box is in nuetral. Start and take diff lock off. Stop engine.
Try high ratio. Jack a rear wheel, test diff lock on and off.
Test drive and check box temperature when returning .
Rear Diff refurbishment Project
> >>> 607181 Outer Diff Pinion Bearing - Sailsbury Axles
> >>> 607180 Inside Pinion Bearing - 4-Pin - Defender
> >>> 607183 Pinion Oil Seal Gasket
> >>> RTC1010 Use AAU3381
> >>> AAU3381 Use AEU2515
> >>> AEU2515 Outer Diff Pinion Oil Seal - Sailsbury
> >>> Axles - Defender to WA159806/Series/101
> >>> AEU2515G Sailsbury Pinion Oil Seal (Leather) - Defender to
> >>> WA159806/Series/101 ? 2.53
> >>> 607197 Crush Spacer - Pinion - 4-Pin - Defender
> >>> 607177 Shim - Diff Pinion - 0.003in
> >>> 607178 Shim - Diff Pinion - 0.005in
> >>> 607179 Shim - Diff Pinion - 0.010in
Other useful parts in area
Front output shaft
217325 Front output Ball Bering SKF RLS10 or LJ 1 1/4C3
571175 Front Output Seal ** see update below
571177 Front Mud Shield
Rear Output Shaft
GRB203 Rear output ball. bearing >>> use STC1130 Timken 6207
594029 Rear output Seal ** see update below
Both seals now replaced with Viton Double lip seals..
1.75x2.75x0.43 inch Viton Rubber Double Lip Rotary Shaft Oil Seal with Spring
45x72x10mm TC / R23 Double Lip Viton Rubber Metric Shaft Oil Seal with Spring
Centre diff
606473 front taper bearing >>>use FRC7871 Timken 32011X
606474 Rear taper bearing Timken JLM 104948/ JLM 104910
608142 LT95 Replacement Pinion Set inc copper washers.
HD230 Pin Heavy Duty Centre Diff Cross Pin (Ashcroft Transmissions)
606754 LT95 Gasket Set Bought previously.
Rear Diff refurbishment Project
> >>> 607181 Outer Diff Pinion Bearing - Sailsbury Axles
> >>> 607180 Inside Pinion Bearing - 4-Pin - Defender
> >>> 607183 Pinion Oil Seal Gasket
> >>> RTC1010 Use AAU3381
> >>> AAU3381 Use AEU2515
> >>> AEU2515 Outer Diff Pinion Oil Seal - Sailsbury
> >>> Axles - Defender to WA159806/Series/101
> >>> AEU2515G Sailsbury Pinion Oil Seal (Leather) - Defender to
> >>> WA159806/Series/101 ? 2.53
> >>> 607197 Crush Spacer - Pinion - 4-Pin - Defender
> >>> 607177 Shim - Diff Pinion - 0.003in
> >>> 607178 Shim - Diff Pinion - 0.005in
> >>> 607179 Shim - Diff Pinion - 0.010in