LAND ROVER DISCOVERY 1999 Workshop Manual

TRANSFER BOX - LT230SE
41-46 OVERHAUL
14.Lubricate and fit 'O' rings to main casing and
intermediate shaft.
15.With assistance, position intermediate gear
assembly and fit intermediate shaft.
16.Rotate shaft until retaining plate can be located
on flat on shaft.
17.Apply sealant, Part No. STC 50552 to threads
of retaining plate bolt, tighten bolt to 25 Nm (18
lbf.ft).
18.Fit new intermediate shaft nut and tighten to 88
Nm (65 lbf.ft).Do not stake nut at this stage.
19.Select neutral.
20.Screw a suitable bolt into tapped hole of tool
LRT-41-005.
21.Insert tool LRT-41-005 in end of mainshaft.
22.Using a suitable torque meter on tool LRT-41-
005, check torque to turn of gear train. Torque
to turn = 2.2 Nm (19 lbf.ft). If torque to turn
figure is incorrect, repeat intermediate gear
bearing pre-load setting and re-check.
23.On completion, remove tool LRT-41-005 and
stake flange of nut into recess on intermediate
shaft.
24.Clean transfer box bottom and side covers.
25.Apply sealant, Part No. STC 4600 to bottom
and side covers.
26.Clean bottom and side cover bolt threads.
27.Apply sealant, Part No. STC 50552 to bolt
threads.
28.Position side cover and tighten bolts to 25 Nm
(18 lbf.ft).
29.Position bottom cover and tighten bolts to 25
Nm (18 lbf.ft).
Differential assembly
$% 41.20.13
Remove
1.Remove intermediate gear cluster.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Intermediate gear assembly.
2.Remove 6 bolts securing high/low cross shaft
housing, multiplug bracket and cable bracket to
front output shaft housing; remove brackets
and housing.

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
41-48 OVERHAUL
15.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut, steel and felt
washers; remove output shaft drive flange.
16.Using a copper mallet, drive output shaft from
housing, recover bearing spacer.
17. If fitted: Noting its fitted position, remove dog
clutch from output shaft. 18.Remove and discard oil seal from housing.
19.Remove and discard circlip retaining output
shaft bearing.
20.Support housing and drift out output shaft
bearing.
21.Remove and discard differential bearing track
and collect selective shim.

TRANSFER BOX - LT230SE
OVERHAUL 41-49
22.Remove plug securing high/low selector shaft
detent spring and ball, remove spring and ball.
23.Withdraw differential assembly together with
high/low selector shaft and fork.
24.Remove selector fork and shaft from
differential.
Note: Selector fork fitted to 03 MY onwards
illustrated.
25.Note position of shoulder bolt, remove 6 bolts
and remove rear output shaft housing.
26.Remove rear bearing track from main casing.
27.Secure differential in a soft jawed vice.
28.Release staking from bearing retaining nut.
29.Using tool LRT-41-007 remove and discard
bearing retaining nut.

TRANSFER BOX - LT230SE
41-50 OVERHAUL
30.Position tool LRT-99-002 to vice.
31.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.
32.Remove high range gear and bush.
33.Make suitable alignment marks between high/
low selector sleeve and hub, remove selector
sleeve.

TRANSFER BOX - LT230SE
OVERHAUL 41-51
34.Using a suitable press and thrust button LRT-
41-001 remove high/low hub and low range
gear.
35.Position tool LRT-41-002 around front
differential bearing and tool LRT-41-001 t h r u s t
button to differential shaft and press off
bearing. Disassembly
1.Secure rear half of differential carrier in a soft
jawed vice.
2.Make suitable alignment marks between front
and rear halves of differential carrier.
3.Remove 8 bolts securing front half of carrier to
rear and separate both halves of carrier.
4.Suitably identify front sun gear to front half of
carrier, then remove sun gear.
5.Remove and discard thrust washer.
6.Suitably identify each planet gear to its shaft
and fitted position of each cross shaft to rear
half of carrier
7.Remove retaining ring.
8.Remove planet gears and cross shafts, remove
and discard dished thrust washers.
9.Suitably identify rear sun gear to rear half of
carrier, then remove sun gear.
10.Remove and discard thrust washer.

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
41-54 OVERHAUL
20.Check high/low selector fork for cracks and
wear. Check selector fork finger width.
lFinger width = 7.37 to 7.47 mm (0.290 to
0.294 in).
21. 03 Model Year onwards: Check high/low
selector fork clips for wear and damage. Check
spring for distortion, check free length of spring:
lSpring free length = 75 mm (2.95 in)
Note: High/low selector shaft, fork and spring
fitted to 03 Model Year transfer boxes may be
fitted to pre 03 Model Year boxes as an
assembly.
22.Check differential sun and planet gears for
wear, cracks and chipping of teeth.
23.Check cross shafts and recesses in both halves
of differential carrier for damage and
wear.Ensure planet gears are retained with
their respective shafts.
24.Check retaining ring for distortion.
25.Check differential splines for wear and
damage.26.Check high/low hub for cracks, chipping and
uneven wear. Check width of selector fork
groove.
lGroove width = 7.5 to 7.6 mm (0.295 to 0.30
in).
27.Check splines and teeth on high/low selector
sleeve for uneven wear, cracks, damage and
chipping.
28.Check teeth of high and low range gears for
cracks, chipping and uneven wear.
29.Check high range gear bush for wear and
damage.

TRANSFER BOX - LT230SE
OVERHAUL 41-55
Reassembly
1.Lubricate all components with recommended
oil and lightly oil the differential bolt threads.
2.Secure rear half of differential carrier in a soft
jawed vice.
3.Fit each planet gear to its respective cross
shaft, fit new dished thrust washer to each
gear.
4.Fit cross shafts, planet gears and dished thrust
washers in rear half of carrier.Ensure that
cross shafts are fitted correctly. Do not fit
the sun gear into the rear half carrier at this
stage.
5.Fit retaining ring.
6.Fit a 1.05 mm (0.04 in) thrust washer to sun
gear from front half of carrier. Position gear in
front half of carrier.
7.Ensuring that assembly marks are aligned, fit
both halves of carrier together.
8.Fit the differential carrier bolts and, working in a
diagonal sequence, tighten the bolts to 60 Nm,
(44 lbf.ft).9.Insert the front output shaft into the front half of
the carrier and check that the gears rotate
freely.
10.Fit output flange on to the splines of the output
shaft, but do not fit flange nut at this stage.
11.Fit transmission brake drum to output flange
and secure the drum using 2 nuts.
12.Secure a length of cord around the drum and
attach one end of the cord to a spring balance.
13.Pull on the spring balance and note the load at
which the brake drum starts to turn. Used
gears should rotate smoothly, while new
gears will have a 'notchy' feel as they rotate.
14.Compare the figure obtained with the following.
lUsed gears = 0.45 kg (1.0 lb)
lNew gears = 1.72 kg (3.8 lb)
15.If the load to turn figure is below the specified
limits, proceed as follows.
16.Remove the front output shaft and brake drum.
17.Remove the 8 bolts securing the two halves of
the differential carrier
18.Separate the differential carrier and remove the
sun gear and thrust washer from the front half.
19.Select a thicker thrust washer from the range
available. 5 different thrust washers are
available, rising in increments of 0.10 mm
(0.004 in) from 1.05 mm to 1.45 mm (0.04 to
0.06 in).
20.Repeat steps 7 to 19 as necessary until the
load to turn figure is as specified
21.When specified load to turn is obtained,
proceed as follows.
22.Remove the front output shaft and brake drum.
23.Remove the 8 bolts securing the two halves of
the differential carrier
24.Separate the differential carrier and remove the
sun gear and thrust washer from the front
half.Retain the selected thrust washer with
its sun gear.