fuel LAND ROVER DISCOVERY 1999 Workshop Manual

TRANSFER BOX - LT230SE
41-14 DESCRIPTION AND OPERATION
Mainshaft input gear
The gearbox output shaft is splined into the mainshaft input gear which is supported by taper roller bearings.
Input gear bearing pre-load is achieved by the use of a selective shim located in the bearing housing.
Intermediate gears
The intermediate gear cluster is supported by the taper roller bearings located at each end of the cluster and runs on
the intermediate shaft which, in turn, is supported at the front and rear by the main casing.
A selective spacer, positioned between the gears, pre-loads the intermediate gear bearings when the intermediate
shaft nut is tightened sufficiently to achieve the correct 'torque to turn' of the intermediate gears.
On vehicles from 03 model year, the circlips used to retain the bearings in the intermediate gear are deleted. The bore
of the intermediate gear is machined with a shoulder at each end to locate the bearings.
Differential assembly
The differential assembly is supported at the front and rear by taper roller bearings, the front bearing outer track is
located in the front output housing and the rear bearing outer track is located in the main casing by the rear output
housing. Bearing pre-load is achieved by means of a selective shim located in the front output housing.
The differential rear shaft carries the low range gear, high/low selector sleeve and hub, high range gear and bush and
the differential rear bearing; these components being secured to the shaft by a special staked nut.
The differential assembly comprises front and rear half carriers with integral shafts and with sun and planet gears
mounted on cross shafts within the half carriers. Dished, non-selective thrust washers control the engagement of the
planet gears with the sun gears, whilst selective thrust washers are used to control engagement of the sun gears and
'torque to turn' of the differential. The differential carrier halves are bolted together, a retaining ring providing positive
location of the cross shafts.
The high/low selector shaft and fork are located at the side of the differential, movement of the shaft, fork and selector
sleeve being controlled by the high/low selector finger. A spring loaded detent ball fitted in the main casing, locates
in grooves in the shaft.
On vehicles from 03 model year, the selector fork is modified and fitted with a spring assister and clips to reduce the
effort required to move the selector lever.
Front output housing
The front output housing carries the front output shaft and flange, high/low cross shaft, housing and selector and on
certain vehicles, the differential lock selector shaft and fork.
The front output shaft is supported in the housing by a single bearing and is splined into the differential front sun gear.
High/low selector
The high/low cross shaft is located in a housing bolted to the top of the output housing and is connected to the high/
low selector finger which locates in a slot in the selector shaft.
High/low detect switch
A high/low detect switch is fitted in the front output housing and connects to earth when low is selected. The switch is
connected to the engine ECM, the SLABS ECU and the EAT ECU. The purpose of the switch is to enable selection
of the hill descent feature and to modify the engine fuelling and automatic gearbox gearshift maps stored within the
respective ECM's and ECU's.
Differential lock - If fitted
The differential lock selector housing is bolted to the top of the front output housing, the selector finger passes through
the housing, locating in a slot in the differential lock selector shaft. The differential lock selector shaft passes through
the selector fork which is located beneath a plate bolted to the side of the output housing. The selector fork engages
the dog clutch sleeve with the differential rear shaft when the splines of the sleeve and differential rear shaft are
aligned. A spring loaded detent ball fitted in the output housing locates in grooves in the shaft.

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
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.

BRAKES
70-6 DESCRIPTION AND OPERATION
Brake servo assembly
The brake servo assembly provides power assistance to reduce the pedal load when braking. If the brake servo
assembly fails, the hydraulic system still functions but will require greater brake pedal effort due to the lack of vacuum
assistance.
Two integral tie bolts attach the brake servo assembly to the pedal and bracket assembly on the engine bulkhead.
The master cylinder assembly is attached to the forward ends of the tie bolts.
The brake servo assembly consists of a circular housing which contains two diaphragms, a central plate, a control
valve assembly, input and output push rods and a filter. The input push rod is connected to the brake pedal. The output
push rod locates in the primary piston of the master cylinder. A protective gaiter is installed on the control valve
assembly where it extends from the rear of the housing. A non return valve, installed in a port in the front face of the
housing, is connected to a vacuum line from the engine.
The control valve assembly consists of a valve body containing a valve, a piston, a valve spring and an input rod
spring. The valve controls a vacuum port in the valve body. The piston controls an air inlet port between the valve and
the piston. A reaction disc and a ratio disc separate the piston from the output push rod. A guide tube on the front of
the valve body is attached to the front diaphragm and supported in a bush in the central plate. A return spring locates
in the open end of the guide tube.
The two diaphragms and the central plate separate the interior of the housing into four sealed chambers. The
chambers at the front of the diaphragms are connected together through fixed passages in the valve assembly. The
chambers at the rear of the diaphragms are connected together through the interior of minor diaphragms on the tie
bolts.
Brakes off
With the brake pedal released, the piston in the control valve assembly positions the valve so that the vacuum port is
open and the two pairs of chambers are connected together. When the engine is running air is evacuated through the
vacuum line and non return valve, creating a partial vacuum in all four chambers. When the engine stops, the non
return valve closes to maintain the partial vacuum and, on V8 models, prevent fuel vapour entering the brake servo.

CHASSIS AND BODY DIMENSIONS
77-1-14 BODY DIMENSIONS
Front end/side information
Gaps
The tolerance for gap 'e' is ± 1.0 (0.039), and for gap 'x' is ± 0.5 (0.019).
Profile
Section Gap Description Dimension
E-E e Bonnet to wing 6.0 (0.236)
x Fuel filler lid to body side panel 3.0 (0.118)
Section Description Dimension
E-E Profile of bonnet to wing +1.0 (0.039) -0.0

PANEL REPAIRS
REPAIRS 77-2-41
Refit
1.Fit side drip rail finisher.
2.Fit wiring to 'B/C' post and sill areas.
3.Fit front and rear door door aperture seal.
4.Position carpet and secure with fixings.
5.Fit tread plates to front and rear door apertures.
6.Fit head lining.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
8.Fit front seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
9. LH side: Fit CD autochanger.

+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
10. RH side: Fit power amplifier.

+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
11.Fit RH or LH front seat.

+ SEATS, REPAIRS, Seat - front.
12.Fit sill finisher.
13.Fit front door striker to B/C post, fit Torx bolts
and tighten to 26 Nm (19 lbf.ft).
14.Fit rear door.

+ DOORS, REPAIRS, Door - rear.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Panel body side assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove loadspace side trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
4.Remove head lining rear trim finisher.
5.Remove rear head rests, if fitted.
6.Remove body side rear glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
7.Remove rear bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
8.Remove rear bumper finisher.
9.Remove rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
10.Remove mud flap.
11.Remove tread plate from rear door aperture.
12.Remove rear door aperture seal.
13.Remove rear door striker from 'D' post.
14.Remove 'D' post outer trim finisher.
15.Remove wheel arch trim finisher.
16.Remove side drip rail finisher.
17. RH side: Remove tail door.
18. LH side: Remove tail door striker and setting
block from 'E' post.
19.Remove tail door tread plate.
20.Remove loadspace carpet retainer.
21.Remove tail door aperture seal.
22.Remove tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
23. RH side: Remove fuel filler flap.
24. RH side: Remove fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
25.Remove aerial amplifier.
26.Remove relevant wiring from body side area.

PANEL REPAIRS
77-2-42 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. The panel
body side assembly does not require any
welding, as it is bolted into position.Refit
1.Position and secure wiring.
2.Fit aerial amplifier.
3. RH side: Fit fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
4. RH side: Fit fuel filler flap.
5.Fit tail lamp.

+ LIGHTING, REPAIRS, Lamp - tail.
6.Fit tail door aperture seal.
7.Fit loadspace carpet retainer.
8.Fit tail door tread plate.
9. LH side: Fit tail door striker and setting block to
'E' post, fit Torx bolts and tighten to 26 Nm (19
lbf.ft).
10. RH side: Fit tail door.
11.Fit side drip rail finisher.
12.Fit wheel arch trim finisher.
13.Fit 'D' post outer trim finisher.
14.Fit rear door striker.
15.Fit rear door aperture seal.
16.Fit tread plate to rear door aperture.
17.Fit mud flap.
18.Fit rear wheel arch liner.

+ EXTERIOR FITTINGS, REPAIRS,
Liner - wheel arch - rear.
19.Fit rear bumper finisher.
20.Fit rear bumper assembly.

+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - rear - up to 03MY.
21.Fit body side rear glass.

+ SCREENS, REPAIRS, Glass - body
side - rear.
22.Fit rear head rests, if fitted.
23.Fit head lining rear trim finisher.
24.Fit loadspace side trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
25.Connect leads/multiplug to alternator.
26.Connect battery leads, negative lead last.
M77 0000

PANEL REPAIRS
REPAIRS 77-2-43
Body side inner rear assembly
In this procedure, the panel body side assembly is
replaced in conjunction with the body side inner rear
assembly.
Remove
1.Disconnect battery eath lead.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove RH or LH rear seat.

+ SEATS, REPAIRS, Seat - rear.
5.Remove loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
6.Remove rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
7.Remove third row seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
8.Remove fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
9.Remove fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
10. RH side: Remove fuel flap release solenoid.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
11. RH side: Remove air extractor vent.
12.Remove relevant wiring.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2. RH side: Fit air extractor vent.
3. RH side: Fit fuel flap release solenoid.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Solenoid - fuel filler flap release.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Solenoid - fuel filler flap release.
4.Fit fuel filler tube.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Filler tube - fuel.
5.Fit fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
6.Fit third row seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belts - third row.
7.Fit rear side seat belt.

+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - rear - side.
8.Fit loadspace carpet.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
9.Fit rear seat.

+ SEATS, REPAIRS, Seat - rear.
10.Fit panel body side assembly.

+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
M77 1698A

PANEL REPAIRS
REPAIRS 77-2-49
Cross member outer rear panel
(RH/LH section)
In this procedure, the panel body side assembly and
the 'E' post assembly are replaced in conjunction
with either the RH or LH section of the cross member
outer rear panel.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove 'E' post assembly.

+ PANEL REPAIRS, REPAIRS, 'E' post
assembly.
4.Remove rear folding step.

+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
5. LH side: Remove exhaust tailpipe heatshield.
6.Remove relevant wiring.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2. LH side: Fit exhaust tailpipe heatshield.
3.Fit rear folding step.

+ EXTERIOR FITTINGS, REPAIRS,
Rear folding step.
4.Fit 'E' post assembly.

+ PANEL REPAIRS, REPAIRS, 'E' post
assembly.
5.Connect leads/multiplug to alternator.
6.Connect battery leads, negative lead last.
Cross member closing rear panel
In this procedure, the cross member outer rear panel
is replaced in conjunction with the cross member
closing rear panel. The cross member rear assembly
can also be replaced, if required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove cross member outer rear panel.

+ PANEL REPAIRS, REPAIRS, Cross
member outer rear panel.
4.Remove fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
5.Remove 2 rear bolts securing body rear to
chassis.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit 2 rear bolts securing body rear to chassis
and tighten to 45 Nm (33 lbf.ft).
2.Fit fuel tank.

+ FUEL DELIVERY SYSTEM - V8,
REPAIRS, Tank - fuel.

+ FUEL DELIVERY SYSTEM - Td5,
REPAIRS, Tank - fuel.
3.Fit cross member rear outer panel.

+ PANEL REPAIRS, REPAIRS, Cross
member outer rear panel.
4.Connect leads/multiplug to alternator.
5.Connect battery leads, negative lead last.

CORROSION PREVENTION AND SEALING
77-4-2 CORROSION PREVENTION
Cavity wax treatment area and injection
hole - fuel filler neck
1Injection hole for fuel filler neck