LT230 replacement not going well!

[Surfin Elvis]

I have installed a used LT 230 t-case, it is mounted flush against output shaft end of auto trans. Trying to get rear cover back on the t-case, but it seems the rear carrier bearing (or the shaft it is on) has been pushed 1-1.5 inches towards the rear of the truck. The round 6-bolt cover cannot be installed flush against the t-case, and I'm afraid to try to force it in with the bolts. Not a good description, but I'm really exhausted. Trying to post a pic, but not having luck right now.
Any thoughts?

 

[discostew]

Make sure you have the transmission in neutral, I always take that shaft off the end of the trans. If you take that 18mm head bolt loose it should pull right off the tail shaft. I think maybe your trans not being in nuetral and your t case not being able to turn freely because your wheels are on the ground might be keeping that gear cluster from rotating into position. Since it's helical cut something is going to need to rotate for it to make it to the fully seated position.

 

[Surfin Elvis]

Thank you! The t-case is free to move as no prop shafts are connected yet. Never thought to undo the bolt on the end of the trans output shaft. Guess I need to pull the t-case off to make this happen?

 

[discostew]

Thank you! The t-case is free to move as no prop shafts are connected yet. Never thought to undo the bolt on the end of the trans output shaft. Guess I need to pull the t-case off to make this happen?

No. Just reach in there and pull that big input gear cluster off the input shaft of the t case. It will rotate slightly while its coming out and make sure you pay attention to what is frt and rear. Then the shaft will pull straight off the tailshaft of the trans once that 18mm bolt head is spun off. Unless this is a standard trans truck. Then that shaft is part of the trans.

 

[Surfin Elvis]

I will try that tonight when I get home, but I can't get the rear carrier bearing to move at all! Gotta get that off first! If I unbolt the 18mm tailshaft bolt, I guess I can pull the whole thing out as one unit? Tried to follow this process, but I did not remove the back cover from the new t-case before installing. When it would not push up against the trans, I then removed the bolts from the rear cover.
http://forums.lr4x4.com/index.php?showtopic=14601

 

[discostew]

I will try that tonight when I get home, but I can't get the rear carrier bearing to move at all! Gotta get that off first! If I unbolt the 18mm tailshaft bolt, I guess I can pull the whole thing out as one unit? Tried to follow this process, but I did not remove the back cover from the new t-case before installing. When it would not push up against the trans, I then removed the bolts from the rear cover.
http://forums.lr4x4.com/index.php?showtopic=14601

The bearings are going to come with the whole gear cluster. You have something in a bind if that whole clusre wont come out easily by hand. You might want to loosen some of the bolts holding the t case to the trans. Google search for some exploded views of that t case. It kind of looks like those pics are of a standard trans truck. But notice he's got the gear cluster I'm talking about out as an assembly with both bearings still attached.

 

[JohnC]

What year T/C are you using?

When I swapped a '97 DI T/C into my '95 DI transmission I had to swap out a shaft. Just a thought.

 

[Mongo]

did you put the bolts back in the correctly...

 

[discostew]

did you put the bolt back in the correctly...

Ya I forgot about that. For sure one of those bolts is short and it hits that gear if its the wrong one.

 

[Ren Ching]

John C has it I think. You may need to change the tailshaft for one with longer splines.

 

[ezzzzzzz]

The whole assembly will come out (after removing the retaining bolt of the shaft) if the ZF is in neutral but pulling the input gear first is easiest. The props are already removed so that isn't an issue. The shaft should have the longer splines found on later models. The 2 short bolts go up front as they enter into the housing (there are only two up front). The input gear installs with the gear towards the front. If you try to install the gear backwards it will foul and the rear bearing will sit approximately 1/2" out from the case.
Side note, if you think of pulling the bottom cover to reseal use heat on the case where the bolts go in. Keep it applied until the bolts can be turned out with minimal effort or at least one is going to break...I garrentontee you that. All of those holes are blind except the 2 lowest and closest to the drain plug. Tap these holes (8-1.25) and die the bolts then apply anti-seize on install.

 

[Surfin Elvis]

Thanks so much for the picture of the splines. I believe that may be my problem. I don't understand, though, since I removed a damaged lt230 difflock and replaced it with a non difflock model. The splined shaft worked with the old t-case.
Either way, I am checking it out in the morning.
Thanks to all for the great response!

 

[ezzzzzzz]

By the way, is this Chuck? Robert Davis and I came over a few years back. We picked up a V8 and I bought a bunch of series bits from a friend of yours too. You had the garage filled including a beautiful Corvette.

 

[Surfin Elvis]

Yep, it's Chuck! I called Robert last night to ask him about my problem. I hope you guys scored well on that part-hunting trip.
I will be taking some pics in a bit and posting them.

 

[Surfin Elvis]

http://s1368.photobucket.com/user/Chuck_Ward/media/Mobile%20Uploads/image_zpsimh46fjw.jpeg.html?filters[user]=140126802&filters[recent]=1&sort=1&o=0

I may take the shaft to a machine shop and have the splines extended, but not sure if there is an exact tolerance on the length of the splines.

Found this link and now I realize that my old t-case did not have the cross-drilled shaft, which is why it worked on the short-splined shaft.
http://www.pirate4x4.com/forum/land-rover/798704-how-divorce-lt230.html
Looks like I can have the splines cut, unless I can find the right shaft quickly!

 

[Surfin Elvis]

Buckhorn Imports to the rescue!!
Shaft is on its way.
Hopefully back together real soon!

 

[ezzzzzzz]

Awesome news!

 

[Surfin Elvis]

Yep, short splined shaft was the problem! Received part from buckhorn imports today via USPS, and everything fit right!
I can't thank all of you enough!!

 

[JohnC]

Your welcome!

 

[Surfin Elvis]