differential LAND ROVER DISCOVERY 1995 User Guide

TRANSFER GEARBOX
3
DESCRIPTION AND OPERATION DIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY
1. Differential selector assembly
2. Front output housing
3. High-low ratio cross shaft assembly
4. High-low selector shaft and lever
5. High-low selector fork and shaft
6. High-low selector finger
7. Differential lock selector shaft
8. Differential lock selector fork
9. Differential lock spring and clips
10. Front output housing cover and housing
11. Felt washer, steel washer and flange nut
12. Front output flange
13. Mud shield
14. Oil seal
15. Bearing
16. Spacer
17. Circlip
18. Differential carrier, front half19. Differential carrier, rear half
20. Retaining ring
21. Front output shaft
22. Dog clutch, front drive lock-up
23. Selective shim
24. Bearing
25. Selective thrust washers
26. Sun and planet gears
27. Thrust washers
28. Cross shafts
29. Gear low
30. Hub and sleeve assembly
31. High output gear
32. Bush
33. Bearing
34. Bearing retaining nut
35. Differential lock switch
36. Differential lock detent ball and spring

41TRANSFER GEARBOX
2
REPAIR Remove
1.Site vehicle on a ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl from radiator.
4.Remove transfer gear lever knob and gaiter.
5.Raise vehicle on ramp [hoist].
6.Drain oil and refit plug.
7.Detach heat shield at front exhaust pipe to
manifold.
8.Disconnect electrics to Lambda sensors.
9.Remove catalytic converter assembly.
10.Remove chassis crossmember from under
gearbox.
11.Remove heat shield from speedometer cable at
transfer gearbox.
12.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
13.Mark for reassembly then disconnect propeller
shaft to output flange, tie to one side.
14.Repeat on front propeller shaft to output flange.
15.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
16.Place four 30mm long spacers between top of
hoist and adaptor plate, at securing points, and
secure adaptor plate to hoist.17.Remove four central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer gearbox.
18.Adjust hoist to take weight of transfer gearbox.
19.Remove tie bar, transfer gearbox to main
gearbox.
20.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
21.Repeat for left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket.
22.Remove right side mounting bracket to flexible
mounting rubber.
23.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
24.Loosen park brake adjustment nut.
25.Remove park brake drum.
26.Remove park brake assembly complete from
rear output flange.
27.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
28.Remove banjo bolt from breather pipe, retrieve
sealing washers and lay pipe aside.
29.Remove split [cotter] pin and washers securing
differential lock to connecting rod and disconnect
rod from lever.
30.Select low range transfer gearbox position.
31.Remove high/low rod lower lock nut and remove
rod from yoke.
32.Position hoist jack channel under bell housing.
33.Using wooden block support the main gearbox
and bell housing.
34.Remove upper and lower bolts securing transfer
gearbox to main gearbox.
35.Fit guide studs 18G 1425 to main gearbox and
move transfer gearbox rearwards to detach.

TRANSFER GEARBOX
3
REPAIR Refit
36.Select 'P' in main gearbox, with low range and
differential lock selected in transfer gearbox.
37.Secure transfer gearbox to adaptor plate on
lifting hoist.
38.Ensure joint faces of transfer and main
gearboxes are clean and guide studs 18G 1425
are fitted.
39.Raise hoist until transfer gearbox can be located
over guide studs to main gearbox. At the same
time locate high/low lower link to yoke.
40.Remove guide studs and secure transfer
gearbox to main gearbox.41.Complete refitting by reversing removal
procedure, noting the following important points.
42.After removal of adaptor plate from transfer
gearbox, clean threads of four bottom cover
bolts, coat threads with Loctite 290 and fit
together with spring washers. Tighten to
25Nm
43.Add correct grade of oil to transfer gearbox to oil
level plug hole.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
44.Check main gearbox oil level.
45.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

TRANSFER GEARBOX
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
LT230T Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................
Shiftlock
Shiftlock screws 9..........................................................................................
Neutral switch 25............................................................................................

41TRANSFER GEARBOX
2
SPECIFICATIONS, TORQUE LT230T TRANSFER GEARBOX DATA
High range gear end - float 0,05 to 0,15 mm..............................................
Front differential bearing pre - load 0.56 to 1.69 Nm..................................
Input gear bearing pre - load 0.56 to 2.25 Nm............................................
Intermediate shaft bearing pre - load 0.56 to 1.69 Nm...............................
JOINT SEALANT
Joint faces use BLS. 22SE03 TYPE 2.................................................................
Shiftlock solenoid cover HYLOSIL RTV...................................................
Neutral switch HYLOMAR...................................................................

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

PROPELLER SHAFTS
1
DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT
Description
The front and rear propeller shafts have non-constant
velocity 'Hooks' type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and sealed.
The rear shaft is fitted with a conventional joint at
gearbox end and the sliding joint sealed with a rubber
gaiter. An SGF rubber coupling is fitted at the
differential end of the shaft.
The front shaft which is shorter than the rear is
'Phased', with the joints at each end, A and B
mis-aligned as shown in RR4199.
The phasing is necessary on the front shaft only to
allow for greater variation in angular changes.
Catalyst vehicles
The front shaft is 'phased' as above but is of solid bar
construction.

47PROPELLER SHAFTS
4
REPAIR REAR PROPELLER SHAFT
Service repair no - 47.15.03
NOTE: SGF rubber coupling should be left
attached to propeller shaft. Only remove
coupling from propeller shaft if
replacement is required.
Remove
1.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
2.Remove three nuts and bolts securing flexible
coupling to axle flange.
3.Remove nuts securing propeller shaft flange to
transfer gearbox.
4.Raise propeller shaft at gearbox end detach
coupling from spigot at differential and withdraw
shaft.
NOTE: For replacement of spigot (pinion
flange centralising peg).
See REAR AXLE
AND FINAL DRIVE, Overhaul, Axle
Differential Assembly
Overhaul
Service repair no - 47.15.12
NOTE: Refer to front propeller shaft
overhaul procedure for gearbox end of
shaft. The SGF rubber coupling is a
non-serviceable item.
Refit
5.Locate flexible coupling over spigot, align
scribed marks and secure at transfer gearbox.
Tighten to
47 Nm.
6.Secure flexible coupling to axle flange with three
nuts and bolts and Tighten to
78 Nm.
FLEXIBLE COUPLING
NOTE: Flexible coupling should only be
removed if a new coupling is to be fitted.
Remove
1.Remove rear propeller shaft.
See Rear
Propeller Shaft.
2.Remove nuts and bolts securing flexible
coupling to propeller shaft.
Refit
3.Reverse removal procedure. Fit nuts and bolts.
Tighten to
78 Nm.