Mother Country Trail 2018, Day T-36: Out-Putting

The electricity now restored and civilization restored to the homestead, it was time to really crank up the action.

Unfortunately, Tuesday was lost to a pretty massive migraine. On Wednesday, I decided it might be a good idea to print out the LT230Q repair manual at the office, and look at it on paper, instead of on my phone. When I started really leafing through it, I realized there was a sort of order of operations I was only half following, so I decided to jump on the bandwagon, better late than never.

First up was disassembling the front output housing completely. I took the flange off using one of my favorite tricks — 30mm socket on an impact gun, nevermind the special flange grabbing tool mentioned in the manual — and pulled the various internals in the prescribed order of operations.

Next was measuring tolerances and cleaning things up. It probably wasn’t necessary to measure the width of the openings in the finger of the high-low mechanism, especially since the truck this came out of was apparently a street truck, but why not?

Next up was replacing the output seal. The old one probably didn’t need replacing, but I wanted to do it. I pulled the old with a seal puller, and greased up the new one.

As I was doing this, I realized I actually already had had one on hand. A few years ago I was going to redo the rear output seal because of what I thought was a leak, and I bought a pattern flange from Bearmach via LRDirect. I never used it, but I thought I’d take a peek at the seal and compare and contrast. I was very disappointed in it, and also in the flange (Bearmach has really upped their game in the past few years, and has become a huge North American community supporter, so they may well be better now), so I decided that the Bearmach flange had a perfect life as a flange seating tool, since I don’t have the $1,000 of official service tools to do this job exactly¬†as per the manual!

It was now time for the most basic beginning of the reassembly process. I picked up Loctite 290 on Amazon, the factory spec item, unavailable at my local hardware store. It’s the “wicking grade” stuff, and green, and it’s way, way thinner than the usual red or blue stuff I use. Little things like this I think are worth the spend to do these jobs you don’t want to do again unnecessarily! I just used it on the set screw for the finger of the high-low housing, but even that little bit gave me a sense of accomplishment.

At some point, in the middle of a trippy Grateful Dead jam, I looked at my phone and realized it was 1:00 AM. Since I had work in the morning, I packed it in and headed to bed, which was a bit of a waste of productive time for this insomniac as I wasn’t asleep until 3:00 AM.

Thursday night, against my better health interests, it was back to the garage to disassemble the rear housing. I am not disassembling the center differential or touching anything that involves bearings, races, or preloads, as much as that’s possible. I do have an ambition to get an Ashcroft ATB center diff next year, so I figure I’ll do bearings when I rebuild the case again to install that.

I wrapped up about 11:30 PM, having gotten to the stage of test fitting the front output housing. At this point, the box has to get set aside, and I have to get the truck into the garage on Friday to begin the fortnight or so of major work underneath. I need to pull a few things off of the old transfer case, so it’s time to get dirty and upside down. I’m going to miss working on the bench…

This weekend is extremely ambitious. I have no curling plans — we have a women’s bonspiel at my club — so I have two full days to just work. The goal is to take 500-mile round shakedown run the weekend of 7-8 April, so I have to get cracking.


14 March: A combination of 1970s and 1980s hits, starting with Simon and Garfunkel’s “Bridge Over Troubled Water” at full volume and ending with Lennon’s “Watching the Wheels”

15 March: City Kids Feel the Beat, on recommendation of Bruce Fowler