Outer Limits 4x4 Board

i learn t something new last weekend whilst doing a zf conversion to a county that not all zfs have the same output shaft (contrary to the belief of the guy who sold the conversion to my mate) the 2 shafts have different spline lengths but as most would already know the output shaft is removeable and we sourced one from tr spares in padstow.
it was my first auto conversion on a rover, that flex plate spacer idea is crap imo. but it all went together pretty smooth except the few mismatched parts etc and the running around

i want to put a zf in my 85 county and use the lt230 from my 200tdi defender any more info would be appreciated as i have done a search and cant find any info

LT230's have a known problem with lubrication/wear of the splines in the input gear.

The solution was to increase the length of the splines in the input gear and provide 2 cross drilled holes to improve lubrication.

To accommodate the longer spline in the input gear, a different spud shaft is required for the zf transmission. The spudshaft can be changed without removing the t/case.

There are 2 different output shafts. The one for the Borg Warner viscous chain drive transfer box (as used on Range Rovers) has the shorter splines. The output shaft for the LT230 box has full length splines.

You can use the full length LT230 version for both transfer box types but not the short spline version.

If you're sourcing your ZF from anything other than a Range Rover you should be OK, if it's coming from a Range Rover you might need to get a replacement shaft.

Bush65 wrote:LT230's have a known problem with lubrication/wear of the splines in the input gear.

The solution was to increase the length of the splines in the input gear and provide 2 cross drilled holes to improve lubrication.

To accommodate the longer spline in the input gear, a different spud shaft is required for the zf transmission. The spudshaft can be changed without removing the t/case.

yep right on the mark so that means the zfwe used was out of an earlier rangie then?

defmec wrote:i want to put a zf in my 85 county and use the lt230 from my 200tdi defender any more info would be appreciated as i have done a search and cant find any info

mate what engine is in the county as a diesel gearbox will be no good for petrol v8 and vise versa

cooter wrote:

defmec wrote:i want to put a zf in my 85 county and use the lt230 from my 200tdi defender any more info would be appreciated as i have done a search and cant find any info

mate what engine is in the county as a diesel gearbox will be no good for petrol v8 and vise versa

but i may have a v8 box available

I assume that he must have the LT85 gearbox, which uses the LT230 t/case. The other gearbox used in county's is the LT95, which has the integral t/case.

AFAIK all LT230's have the same gearbox mounting and same input spline size. There are internal differences (gearing etc), handbrake and mounting for handbrake lever, and other differences with disco II.

v8 lt95 but im taking the 230 out of my 200tdi i have noticed that the transfer and gearbox mounts in the county are just bolted to the chassis so if i have to move them it will be easyer

you use the county mounts on the later model box it all bolts up