differential LAND ROVER DISCOVERY 1999 Owner's Guide

TRANSFER BOX - LT230SE
41-24 REPAIRS
Cable - selector - differential lock
$% 41.20.12
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
2.Remove 4 bolts securing transfer gearbox high/
low selector lever to transmission tunnel.
3.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
4. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
5. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low select cable.
6.Release and remove clevis pin and 'C' clip
securing transfer gearbox high/low selector
cable to transfer gearbox high/low selector
lever. Position the cable aside.7.Release and remove clevis pin securing
differential lock selector cable to transfer
gearbox.
8.Loosen locknuts securing differential lock
selector cable to differential lock selector cable
abutment bracket.
9.Release and remove differential lock selector
cable from differential lock selector cable
abutment bracket.
10.Remove transfer gearbox high/low selector
lever assembly from transmission tunnel.
11.Release and remove clevis pin and 'C' clip
securing differential lock selector cable to
differential lock selector lever. Remove the
differential lock selector cable.

TRANSFER BOX - LT230SE
REPAIRS 41-25
Refit
1.Fit differential lock selector cable to differential
lock selector lever and secure with clevis pin
and 'C' clip.
2.Position transfer gearbox high/low selector
lever assembly to transmission tunnel.
3.Position differential lock selector cable to
differential lock selector cable abutment
bracket and tighten locknuts sufficiently to
retain cable.
4.Fit differential lock selector cable to transfer
gearbox and secure with clevis pin.
5.Fit transfer gearbox high/low selector cable to
transfer gearbox high/low selector lever and
secure with clevis pin and 'C' clip.
6.Fit transfer gearbox high/low selector lever to
transmission tunnel, fit bolts and tighten to 10
Nm (7 lbf.ft).
7. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness and secure sleeve.
8. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
9.Check and adjust differential lock selector
cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
10.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
Transfer box - Diesel
$% 41.20.25.99
Remove
1.Remove front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
2.Raise vehicle on ramp.
3.Drain transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
4.Remove 3 nuts securing intermediate silencer
to tail pipe.
5.Release silencer from mounting rubbers.
6.Remove silencer and discard gasket.
7.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
8.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

TRANSFER BOX - LT230SE
41-26 REPAIRS
9.Remove handbrake drum retaining screw and
remove drum.
10.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
11. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
12. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.
13. If fitted: Release and remove clevis pin
securing differential lock selector cable to
transfer gearbox.14. If fitted: Loosen locknuts securing differential
lock selector cable to differential lock selector
cable abutment bracket.
15. If fitted: Release and remove differential lock
selector cable from differential lock selector
cable abutment bracket.
16.Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and release outer cable from abutment bracket.
17. Up to 03 Model Year - if fitted: Disconnect 2
Lucars from differential lock switch and
multiplugs from high/low ratio switch and
neutral sensor.
18.Disconnect multiplug from reverse light switch.

TRANSFER BOX - LT230SE
REPAIRS 41-27
19. 03 Model Year onwards - if fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
20.Remove cable tie and multi plug from bracket
on transfer box.
21.Release transfer box breather pipe from
bulkhead clip.
22.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts. 23.Position gearbox support jack and secure
support plate to jack using 4 bolts.
24.Remove 3 bolts securing transfer box to
gearbox.
25.Fit 3 guide studs LRT-41-009 through
transfer box bolt holes to support it during
removal.
26.Remove 2 bolts and nut securing transfer box
to gearbox.
CAUTION: If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
27.Position a jack to support gearbox and engine.

TRANSFER BOX - LT230SE
41-28 REPAIRS
28.Remove 4 bolts and nut, remove gearbox RH
mounting.
29.With assistance, remove transfer box from
gearbox.
30.Remove input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
Refit
1.Fit new input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
2.Clean transfer box to gearbox mating faces.
3.Raise transfer box on jack and align to guide
studs LRT-41-009.
4.Clean transfer box to gearbox bolt threads.
5.Apply sealant, Part No. STC 50552 to bolt and
stud threads.
6.Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted, apply sealant, Part No. STC 50552 to
stud threads and tighten to 45 Nm (33 lbf.ft).
7.Remove guide studs, fit and lightly tighten
remaining 3 bolts.
8.Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft).
9.Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10.Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11.Remove 4 bolts securing support plate to
gearbox jack.
12.Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
13.Clean bottom plate bolt threads.
14.Apply sealant, Part No. STC 50552 to threads
of 4 bottom plate bolts.
15.Fit 4 bolts securing bottom plate to transfer box
and tighten to 25 Nm (18 lbf.ft).
16.Position breather pipe and secure to bulkhead
clip.
17.Connect multiplug to reverse light switch. 18. Up to 03 Model Year - if fitted : Connect
Lucars to differential lock switch and multiplugs
to high/low ratio switch and neutral sensor.
19. 03 Model Year onwards - if fitted: Connect
differential lock warning lamp multiplugs,
secure harness.
20.Position high/low ratio selector cable and
secure with clevis pin and 'C' clip.
21.Position differential lock selector cable to
differential lock selector cable abutment
bracket and tighten locknuts sufficiently to
retain cable.
22. If fitted: Fit differential lock selector cable to
transfer gearbox and secure with clevis pin.
23. If fitted: Adjust differential lock selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
24. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness; secure sleeve.
25. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
26.Clean handbrake and mating face.
27.Position handbrake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
28.Clean handbrake drum.
29.Fit handbrake drum and tighten retaining
screw.
30.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
31.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
32.Clean exhaust silencer and mating face.
33.Position silencer, fit new gasket , connect
mounting rubbers and tighten nuts to 40 Nm
(30 lbf.ft).
34.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
35.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.

TRANSFER BOX - LT230SE
41-30 REPAIRS
12. If fitted: Release and remove clevis pin
securing differential lock selector cable to
transfer gearbox.
13. If fitted: Loosen locknuts securing differential
lock selector cable to differential lock selector
cable abutment bracket.
14. If fitted: Release and remove differential lock
selector cable from differential lock selector
cable abutment bracket.
15.Remove clevis pin and 'C' clip securing high/
low ratio selector cable to selector lever and
release cable from abutment bracket.
16.Remove 2 cable ties securing cable to fuel
pipes. 17. If fitted: Disconnect 2 Lucars from oil
temperature sensor and disconnect reverse
lamp switch multiplug.
18.Remove banjo bolt securing breather pipe and
discard washers.
19. Up to 03 Model Year - if fitted: Disconnect 2
Lucars from differential lock switch and
multiplugs from high/low ratio switch and
neutral sensor.
20.Disconnect multiplug from reverse light switch.

TRANSFER BOX - LT230SE
REPAIRS 41-31
21. 03 Model Year onwards - if fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
22.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
23.Position gearbox support jack and secure
support plate to jack using 4 bolts. 24.Remove 3 bolts securing transfer box to
gearbox.
25.Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
26.Remove 2 bolts and nut securing transfer box
to gearbox case.
CAUTION: If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
27.Position a jack to support gearbox and engine.
28.Remove 4 bolts and nut securing RH mounting
to body and transfer box.
29.Remove nut securing LH mounting to body.
30.Raise gearbox and remove RH mounting.
31.With assistance, remove transfer box from
gearbox.
32.Remove input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.

TRANSFER BOX - LT230SE
41-32 REPAIRS
Refit
1.Fit new input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
2.Clean transfer box to gearbox mating faces.
3.Raise transfer box on jack and align to guide
studs LRT-41-009.
4.Clean transfer box to gearbox bolt threads.
5.Apply sealant, Part No. STC 50552 to bolt and
stud threads.
6.Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted, apply sealant, Part No. STC 50552 to
stud threads and tighten to 45 Nm (33 lbf.ft).
7.Remove guide studs, fit and lightly tighten 3
bolts.
8.Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft.
9.Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10.Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11.Fit nut to LH mounting and tighten to 48 Nm (35
lbf.ft).
12.Remove 4 bolts securing support plate to
gearbox jack.
13.Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
14.Clean threads of bottom plate bolts.
15.Apply sealant, Part No. STC 50552 to threads
of 4 bottom plate bolts.
16.Fit 4 bolts securing bottom plate and tighten to
25 Nm (18 lbf.ft).
17.Using new washers position breather pipe and
tighten banjo bolt.
18.Connect multiplug to transfer box neutral switch
and secure harness.
19. Up to 03 Model Year - if fitted : Connect
Lucars to differential lock switch and multiplugs
to high/low ratio switch and neutral sensor.
20. 03 Model Year onwards - if fitted: Connect
differential lock warning lamp multiplugs,
secure harness.
21.Connect multiplug to reverse lamp switch.
22. If fitted: Connect Lucars to oil temperature
switch.
23.Position high/low ratio selector cable and
secure with 'C' clip and clevis pin.
24. If fitted: Position differential lock selector cable
to differential lock selector cable abutment
bracket and tighten locknuts sufficiently to
retain cable.
25. If fitted: Fit differential lock selector cable to
transfer gearbox and secure with clevis pin.
26. If fitted: Adjust differential lock selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.27. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness; secure sleeve.
28. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
29.Secure cable to fuel pipes with new cable ties.
30.Clean handbrake back plate and mating face.
31.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
32.Clean handbrake drum.
33.Fit handbrake drum and tighten retaining
screw.
34.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
35.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
36.Clean exhaust silencer and tail pipe mating
faces.
37.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
38.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
39.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
40.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.

TRANSFER BOX - LT230SE
41-34 REPAIRS
Switch - differential lock - Up to 03 MY
$% 41.20.34
Remove
1.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
2.Disconnect 2 Lucars from switch.
3.Remove switch and remove nut from switch.Refit
1.Clean switch and gearbox face.
2.Fit nut to switch with counterbore positioned
towards switch head. The nut acts as a spacer
to ensure that switch setting is correct.
Always ensure that nut is fully tightened to
switch head, (no gap).
3.Apply sealant, Part No. STC 50552 to switch
thread.
4.Position switch into front output housing until
nut bottoms out on housing.
5.Tighten nut securing differential lock switch to
11 Nm (8 lbf.ft)
6.Connect Lucars to switch.
7.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

TRANSFER BOX - LT230SE
41-40 REPAIRS
Solenoid - interlock - Up to 03 MY
$% 41.20.63
Remove
1.Raise vehicle on ramp.
2.Disconnect multiplug from interlock solenoid.
3.Release multiplug retainer from mounting plate
on transfer box.
4.Remove 4 bolts securing solenoid cover,
remove cover and Belleville washer.
5.Remove solenoid.
Refit
1.Clean solenoid cover and mating face.
2.Position solenoid in main casing.
3.Apply sealant, Part No. STC 4600 to solenoid
cover
4.Fit cover and Belleville washer.
5.Fit bolts securing interlock solenoid and tighten
to 10 Nm (7 lbf.ft).
6.Connect and secure multiplug.
7.Lower vehicle on ramp.
Solenoid - interlock - from 03 MY
$% 41.20.63
Remove
1.Remove differential lock selector cable.

+ TRANSFER BOX - LT230SE,
REPAIRS, Cable - selector - differential lock.
2.Remove nut securing lever to selector housing
cross shaft and remove lever from shaft.
3.Release insert from solenoid multiplug, remove
wire terminals and remove multiplug body.
4.Remove sealant from solenoid and gear
selector housing.
5.Remove circlip securing solenoid to gear
selector housing and remove solenoid from
housing.
Refit
1.Fit solenoid to gear selector housing, feeding
harness through hole in housing.
2.Fit circlip to secure solenoid and apply STC
50551 to seal solenoid to housing.
3.Fit wires to multiplug body and fit insert into
multiplug.
4.Fit lever to cross shaft and tighten nut to 25 Nm
(18 lbf.ft).
5.Fit differential lock selector cable.

+ TRANSFER BOX - LT230SE,
REPAIRS, Cable - selector - differential lock.