LAND ROVER DISCOVERY 1999 Workshop Manual

TRANSFER BOX - LT230SE
41-36 REPAIRS
Oil seal - input shaft
$% 41.20.50
Remove
1.Remove transfer box.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.
2.Lever input shaft oil seal from transfer box.
Refit
1.Clean oil seal recess in transfer gearbox.
2.Using tool LRT-37-014 fit input shaft seal to
transfer box.
CAUTION: Oil seal must be fitted dry.
3.Fit transfer box.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.
Seal - front output shaft
$% 41.20.51
Remove
1.Position vehicle on 4 post ramp.
2.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
3.Restrain transfer box drive flange using tool
LRT-51-003. Remove and discard drive flange
nut, remove and discard steel and felt washers.
4.Using tool LRT-99-500 if necessary, remove
drive flange from transfer box.

TRANSFER BOX - LT230SE
REPAIRS 41-37
5.Remove seal from transfer box.
Refit
1.Clean seal mating faces.
2.Fit new seal using tool LRT-41-012.
CAUTION: Oil seal must be fitted dry.
3.Position drive flange, fit new felt and steel
washers.
4.Position tool LRT-51-003 and tighten new
drive flange nut to 148 Nm (109 lbf.ft). 5.Fit propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
6.Top-up transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.

TRANSFER BOX - LT230SE
41-38 REPAIRS
Seal - rear output shaft
$% 41.20.54
Remove
1.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
2.Loosen brake shoe adjuster bolt.
3.Remove screw securing handbrake drum. 4.Remove handbrake drum.
5.Restrain transfer box drive flange using tool
LRT-51-003. Remove and discard drive flange
nut, remove and discard steel and felt washers.
6.Using tool LRT-99-500 if necessary, remove
drive flange from transfer box.
7.Remove seal from transfer box.

TRANSFER BOX - LT230SE
REPAIRS 41-39
Refit
1.Clean seal mating faces.
2.Fit new seal using tool LRT-41-012.
CAUTION: Oil seal must be fitted dry.
3.Position drive flange, fit new felt and steel
washers.
4.Position tool LRT-51-003 and tighten new
drive flange nut to 148 Nm (109 lbf.ft).
5.Position handbrake drum and tighten screw.
6.Tighten brake shoe adjuster bolt to 25 Nm (18
lbf.ft) then loosen one and a half turns.
7.Check that brake drum is free to rotate.
8.Fit propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
9.Top-up transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
Gasket - rear output shaft housing
$% 41.20.55
Remove
1.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
2.Remove rear output shaft seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Seal - rear output shaft.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
1.Clean output shaft housing, mating face on
main casing and sealant from bolt threads.
2.Apply sealant, Part No. STC 4600 to mating
flange on output shaft housing.
3.Fit output shaft housing to main casing.
4.Apply sealant, Part No. STC 50552 to output
shaft housing bolt threads.
5.Fit output shaft housing bolts and tighten by
diagonal selection to 45 Nm (33 lbf.ft).
6.Fit rear output shaft seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Seal - rear output shaft.
7.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.

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.

TRANSFER BOX - LT230SE
REPAIRS 41-41
Sensor - neutral
$% 41.20.64
Remove
1.Raise vehicle on ramp.
2.Disconnect multiplug from neutral sensor.
3.Remove sensor and discard sealing washer.
Refit
1.Clean sensor threads.
2.Fit new washer and apply sealant, Part No.
STC 50552 to threads of sensor.
3.Fit and tighten sensor to 25 Nm (18 lbf.ft).
4.Lower vehicle on ramp.
Sensor - oil temperature - If fitted
$% 41.20.80
Remove
1.Lower vehicle.
2.Disconnect 2 Lucar connectors from oil
temperature sensor.
3.Remove oil temperature sensor and discard
sealing washer.
Refit
1.Clean sensor and mating face on transfer box.
2.Fit new sealing washer, position oil
temperature sensor and tighten to 25 Nm (18
lbf.ft).
3.Connect Lucar connectors to oil temperature
sensor.
4.Lower vehicle.

TRANSFER BOX - LT230SE
41-42 REPAIRS
Switch - high low - warning
$% 41.30.05
Remove
1.Raise vehicle on a ramp.
2.Release switch multiplug from bracket on
transfer box and disconnect from harness.
3.Remove switch from transfer box and discard
sealing washer.
Refit
1.Ensure sealing washer, switch thread and
mating face on transfer box is clean.
2.Fit sealing washer to switch, fit and tighten
switch to transfer box to 25 Nm (18 lbf.ft) .
3.Connect multiplug to harness and fit multiplug
to bracket on transfer box.
4.Lower vehicle.
Switch(es) - differential lock warning
From 03 MY
$% 41.30.06
Remove
1.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
2.Release and disconnect both differential lock
warning switch multiplugs.
3.Remove differential lock front warning switch,
remove and discard sealing washer.
4.Remove differential lock rear warning switch,
remove and discard sealing washer.
Refit
1.Clean switches and mating face on transfer
gearbox.
2.Apply sealant, STC 50552 to switch threads.
3.Use new sealing washers, fit and tighten
differential lock warning switches to 26 Nm (19
lbf.ft)
4.Connect and secure both switch multiplugs.
5.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

TRANSFER BOX - LT230SE
OVERHAUL 41-43
OVERHAUL
Intermediate gear assembly
$% 41.20.10
Disassembly
1.Remove and discard 10 bolts securing bottom
cover, remove cover.
2.Remove 7 bolts securing differential lock
selector side cover.
3.Remove side cover. 4.Release staking from intermediate shaft nut,
remove and discard nut.
5.Remove bolt securing intermediate shaft
retaining plate, remove plate.
6.Remove intermediate shaft and discard 2 'O'
rings.

TRANSFER BOX - LT230SE
41-44 OVERHAUL
7.Remove intermediate gear assembly and
collect bearings and selective spacer.
8.Secure gear assembly in a soft jawed vice and
using a suitable drift, remove and discard
bearing tracks.
9. Up to 03 Model Year:Remove and discard
circlips.Reassembly
1. Up to 03 Model Year:Clean gears, bearings,
circlips, shaft and mating faces of front output
housing, side and bottom covers.
Note: Intermediate gear cluster and bearing
assemblies fitted to 03 Model Year boxes may
be fitted as replacements to pre 03 Model Year
boxes.
2. 03 Model Year onwards:Clean gears,
bearings and shaft.
3. Up to 03 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.

TRANSFER BOX - LT230SE
OVERHAUL 41-45
4. 03 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.
5.Using a micrometer, measure the width of each
bearing inner track. 6.Record each reading as measurement 'A' and
'B', both measurements should fall within the
range of 21.95 to 22.00 mm (0.864 to 0.866 in).
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 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
to 0.64 mm (0.006 to 0.025 in).
10.Using the formula 103.554 mm (4.0769 in) -'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 in). 40 spacers are
available ranging in length from 58.325 mm
(2.296 in) to 59.300 mm (2.335 in) rising in
increments of 0.025 mm (0.001 in).
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.