lock LAND ROVER DISCOVERY 1999 Workshop Manual

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
REPAIRS 41-35
Cable - high/low selector
$% 41.20.43
Remove
1.Raise vehicle on a ramp.
2.Using a suitable crowsfoot spanner, remove
lock nut and washer securing outer cable to
abutment bracket.
3.Remove clevis pin securing inner cable to
transfer box lever and release cable from
abutment bracket.
4.Release 'C' clip securing outer cable to high/
low lever abutment bracket.
5.Remove clevis pin securing inner cable to high/
low lever.6.Remove bolt securing outer cable clip to cross
shaft housing, remove cable.
Refit
1.Clean change levers, abutment bracket and
clevis pins.
2.Apply Mobilith SHC 100 grease to inner cable
ends and clevis pins.
3.Position cable and secure to high/low lever
abutment bracket with 'C' clip.
4.Secure inner cable to high/low lever with clevis
pin.
5.Position outer cable clip to cross shaft housing,
tighten bolt to 15 Nm (11 lbf.ft).
6.Adjust high/low selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - high/low selector.

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
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
OVERHAUL 41-47
3.Note position of longest bolt and remove 8 bolts
securing front output shaft housing to main
casing and remove housing.
Note: Carry out the following operations if
differential lock is fitted.
4. Differential lock fitted: Remove 3 bolts
securing differential lock selector housing and
remove housing.
5. Differential lock fitted: Remove and discard
'O' rings from selector housing.
6. Up to 03 Model Year: Remove Allen plug and
remove differential lock detent spring and ball.
7. Up to 03 Model Year: Remove differential lock
warning lamp switch and locknut.
8. 03 Model Year onwards - differential lock
fitted: Remove 2 differential lock warning lamp
switches and sealing washers.9. 03 Model Year onwards - differential lock
fitted: Note position of longest bolt and remove
8 bolts securing front output housing to main
casing and remove housing.
10. 03 Model Year onwards - differential lock
fitted: Remove 3 bolts securing differential lock
selector housing and bracket, remove bracket
and housing.
11. 03 Model Year onwards - differential lock
fitted: Remove and discard 'O' rings from
selector housing.
12. 03 Model Year onwards - differential lock
fitted: Remove detent plug, recover spring and
ball.
13. All transfer boxes fitted with differential
lock: Compress differential lock selector fork
spring and remove retaining clips from each
end of spring.
14. All transfer boxes fitted with differential
lock: Withdraw differential lock selector shaft
from front output housing, recover spring and
remove selector fork.

TRANSFER BOX - LT230SE
41-52 OVERHAUL
Inspect
1.Check mating surfaces of cross shaft and
housing bore for wear.
2.Check core plug in housing for signs of leakage
or corrosion ; apply sealant, Part No. STC 3811
to replacement plug.
3.Measuring across widest portion of finger,
check high/low selector finger for wear.
lFinger width = 15.90 to 15.95 mm (0.625 to
0.627 in).
4.Check bearing track recesses in housing for
damage, rectify or replace housing as
necessary.
5. If fitted: Carry out inspection of differential
lock components using following procedures.
6.Check differential lock selector shaft and
housing bore for wear.
7.Measuring across the widest portion, check
differential lock finger for wear.
lFinger width = 15.90 to 15.95 mm (0.625 to
0.627 in).Note: Differential lock selector shaft fitted to 03
Model Year onwards illustrated.
8.Check differential lock selector finger groove in
selector shaft.
lGroove width = 16.0 to 16.1 mm (0.63 to
0.64 in).
Differential lock selector shaft fitted to 03 Model Year
onwards illustrated.
9.Check detent grooves in differential lock
selector shaft for wear.
10.Check differential lock detent ball for flat spots
and check detent spring for distortion.

TRANSFER BOX - LT230SE
OVERHAUL 41-53
11.Check differential lock selector fork for cracks
and wear.
12.Check selector fork finger width.
lFinger width = 7.92 to 7.97 mm (0.311 to
0.313 in).
13.Check differential lock selector fork clips for
wear and damage. Check spring for distortion
and free length.
lSpring free length = 84.58 mm (3.33 in).
14.Check dog clutch internal teeth and grooves
and teeth on output shaft for wear and
damage. Check selector fork groove width.
lGroove width = 8.05 to 8.20 mm (0.32 to
0.33 in).
15.Carry out the following inspection procedures
for all transfer boxes.
16.Check threads and splines of output shaft for
damage and wear. Check dog clutch teeth on
shaft for wear and damage.17. 03 Model Year onwards: Compress high/low
selector fork spring and remove retaining clips
from each end of spring, remove high/low
selector shaft.
High/low selector shaft fitted to pre 03 Model Year
illustrated.
18.Check detent grooves in high/low selector shaft
for wear. Do not remove fork from shaft
unless either component is being renewed.
If fork is removed from shaft, coat the
threads of the set screw with sealant, Part
No. STC 50552 prior to assembling.
19.Check width of high/low selector groove.
lGroove width = 16.0 to 16.1 mm (0.63 to
0.64 in).

TRANSFER BOX - LT230SE
OVERHAUL 41-57
Refit
1.Clean differential components. Remove all
traces of sealant from housings and bolts,
differential lock warning lamp switches and
detent plugs.
2.Lubricate components with gearbox oil.
3.Position differential in soft jawed vice and fit
front bearing using tool LRT-41-008. 4.Invert differential in soft jawed vice, and fit low
range gear with dog teeth facing uppermost.
5.Fit high/low hub ensuring that machined
groove on hub teeth faces towards low range
gear.
6.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
7.Fit bush to high range gear ensuring collar is
uppermost.
8.Fit high range gear and bush onto shaft.
9.Fit new rear bearing using tool LRT-41-008.