Intermediate Gear Assembly: Reassembly

NOTE: Intermediate gear cluster and bearing assemblies fitted to 2003 Model Year transfer boxes may be fitted as replacements to pre 2003 Model Year transfer boxes.
1. On vehicles up to 2003 Model Year, clean gears, bearings, circlips, shaft and mating faces of front output housing, side and bottom covers.
2. On vehicles 2003 Model Year onwards, clean gears, bearings and shaft.
3. On vehicles up to 2003 Model Year, fit NEW circlips and using tools LRT-99-003 and LRT-41-006 fit bearing tracks to intermediate gear, ensuring that the bearing tracks are fully seated against the circlips. See Fig 1 .
4. On vehicles 2003 Model Year onwards, using tools LRT-99-003 and LRT-41-006, fit bearing tracks to intermediate gears ensuring that tracks are fully seated against shoulders in gears. See Fig 2 .
5. Using a micrometer, measure the width of each bearing inner track. See Fig 3 .
6. Record each reading as measurement A and B. Both measurements should fall within the range of 21.95-22.00 mm (0.864-0.866").
7. Fit inner bearing track A onto tool LRT-41-017 and position intermediate gear cluster onto bearing A.
8. Fit inner bearing track B to intermediate gear, apply finger pressure to bearing inner track and rotate intermediate gear 5 to 10 turns to settle in bearing rollers.
9. Attach a Dial Test Indicator (DTI) to base of tool LRT-41-017, zero gauge on top of tool post and take 2 measurements at 180° of the step height between the top of the tool post and the bearing inner track. Take an average of the two readings and record this as measurement C. Measurement C should be in the range of 0.15-0.64 mm (0.006-0.025"). See Fig 4 .
10. Using the formula 103.554 mm (4.0769") - A - B - C, calculate the length of bearing spacer required. From the result of the calculation round DOWN to the nearest length of spacer available to give a correct bearing pre-load of 0.005 mm (0.002"). There are 40 spacers available ranging in length from 58.325-59.300 mm (2.335-2.296") rising in increments of 0.025 mm (0.001").
11. Remove intermediate gear assembly from tool LRT-41-017.
12. Lubricate and fit bearings and selected spacer to intermediate gear.
13. Position tool LRT-41-004 through bearings and spacer.
14. Lubricate and fit "O" rings to main casing and intermediate shaft.
15. With assistance, position intermediate gear assembly and fit intermediate shaft.
16. Rotate shaft until retaining plate can be located on flat on shaft.
17. Apply sealant, Part No. STC 50552 to threads of retaining plate bolt, tighten bolt to 25 N.m (18 ft. lbs.).
18. Fit NEW intermediate shaft nut and tighten to 88 N.m (65 ft. lbs.). DO NOT stake nut at this stage.
19. Select neutral.
20. Screw a suitable bolt into tapped hole of tool LRT-41-005.
21. Insert tool LRT-41-005 in end of mainshaft. See Fig 5 .
22. Using a suitable torque meter on tool LRT-41-005, check torque to turn of gear train. Torque-to-turn = 2.2 N.m (19 ft. lbs.). If torque to turn figure is incorrect, repeat intermediate gear bearing pre-load setting and re-check.
23. On completion, remove tool LRT-41-005 and stake flange of nut into recess on intermediate shaft.
24. Clean transfer box bottom and side covers.
25. Apply sealant, Part No. STC 4600 to bottom and side covers.
26. Clean bottom and side cover bolt threads.
27. Apply sealant, Part No. STC 50552 to bolt threads.
28. Position side cover and tighten bolts to 25 N.m (18 ft. lbs.).
29. Position bottom cover and tighten bolts to 25 N.m (18 ft. lbs.).

Fig 1: Installing Bearing Tracks To Intermediate Gear Assembly (Up To 2003 Model Year)

Courtesy of LAND ROVER NORTH AMERICA, INC.

Fig 2: Installing Bearing Tracks To Intermediate Gear Assembly (From 2003 Model Year)

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Fig 3: Measuring Width Of Each Bearing Inner Track

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Fig 4: Measuring For Spacer Length

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Fig 5: Checking Transfer Box Gear Train Torque-To-Turn

Courtesy of LAND ROVER NORTH AMERICA, INC.