oil LAND ROVER DISCOVERY 1999 Workshop Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 550 of 1529
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.
Page 553 of 1529
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.
Page 554 of 1529
TRANSFER BOX - LT230SE
REPAIRS 41-29
Transfer box - V8
$% 41.20.25.99
Remove
1.Remove front exhaust pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
2.Drain transfer box oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
3.Remove 8 bolts securing rear cross member
and remove cross member.
4.Remove 3 nuts securing intermediate silencer
to tail pipe.
5.Release silencer from mounting rubbers,
remove silencer and discard gasket.
6.Remove front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
7.Remove rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.8.Remove handbrake drum retaining screw and
remove handbrake drum.
9.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
10. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
11. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.
Page 555 of 1529
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.
Page 556 of 1529
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.
Page 557 of 1529
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.
Page 558 of 1529
TRANSFER BOX - LT230SE
REPAIRS 41-33
Gasket - rear cover plate
$% 41.20.30
Remove
1.Mark rear cover to bearing housing for
assembly purposes.
2.Note fitted position of stud nut, remove stud nut
and 5 bolts securing rear cover.
3.Carefully release rear cover from bearing
housing. Refit
1.Clean rear cover, mating face on bearing
housing and sealant from stud/bolt threads.
2.Apply sealant Part No. STC 4600 to rear cover
mating face.
3.Align reference marks and position rear cover.
4.Apply sealant, Part No. STC 50552 to stud/bolt
threads, fit rear cover plate stud nut and bolts
and tighten to 25 Nm (18 lbf.ft).
5.Top-up transfer box oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
Page 561 of 1529
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.
Page 562 of 1529
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.
Page 564 of 1529
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.