oil LAND ROVER DISCOVERY 2002 Workshop Manual

TRANSFER BOX - LT230SE
REPAIRS 41-29
22.Remove 4 bolts and nut securing RH mounting
to body and transfer box.
23.Remove nut securing LH mounting to body.
24.Raise gearbox and remove RH mounting.
25.With assistance, remove transfer box from
gearbox.
26.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 Loctite 290 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 Loctite 290 to threads of stud
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 Loctite 290 to threads of 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. If fitted - Connect Lucars to differential lock
switch.
20.Connect multiplug and Lucars to reverse lamp
switch and oil temperature sensor.
21.Position high/low ratio selector cable and
secure with 'C' washer and clevis pin.
22.Secure cable to fuel pipes with new cable ties.
23.Clean handbrake back plate and mating face.
24.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
25.Clean handbrake drum.
26.Fit handbrake drum and tighten retaining
screw.
27.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
28.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
29.Clean exhaust silencer and tail pipe mating
faces.
30.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
31.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
33.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.

TRANSFER BOX - LT230SE
41-30 REPAIRS
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 3254 to rear cover
mating face.
3.Align reference marks and position rear cover.
4.Apply Loctite 290 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.
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 Hylomar PL 32 sealant to switch thread.
4.Position switch into front output housing until
nut bottoms out on housing.

TRANSFER BOX - LT230SE
41-32 REPAIRS
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.
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.Lubricate new input shaft oil seal with gearbox
oil.
3.Using tool LRT-37-014 fit input shaft seal to
transfer box.
4.Fit transfer box.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

TRANSFER BOX - LT230SE
REPAIRS 41-33
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.
5.Remove seal from transfer box. Refit
1.Clean seal mating faces.
2.Lubricate seal with gearbox oil.
3.Fit new seal using tool LRT-41-012.
4.Position drive flange, fit new felt and steel
washers.
5.Position tool LRT-51-003 and tighten new
drive flange nut to 148 Nm (109 lbf.ft).
6.Fit propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
7.Top-up transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.

TRANSFER BOX - LT230SE
41-34 REPAIRS
Seal - rear output shaft
$% 41.20.54
Remove
1.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
2.Loosen brake shoe adjuster bolt.
3.Remove screw securing handbrake drum. 4.Remove handbrake drum.
5.Restrain transfer box drive flange using tool
LRT-51-003. Remove and discard drive flange
nut, remove and discard steel and felt washers.
6.Using tool LRT-99-500 if necessary, remove
drive flange from transfer box.
7.Remove seal from transfer box.
Refit
1.Clean seal mating faces.
2.Lubricate seal with gearbox oil.

TRANSFER BOX - LT230SE
REPAIRS 41-35
3.Fit new seal using tool LRT-41-012.
4.Position drive flange, fit new felt and steel
washers.
5.Position tool LRT-51-003 and tighten new
drive flange nut to 148 Nm (109 lbf.ft).
6.Position handbrake drum and tighten screw.
7.Tighten brake shoe adjuster bolt to 25 Nm (18
lbf.ft) then loosen one and a half turns.
8.Check that brake drum is free to rotate.
9.Fit propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
10.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 3254 to mating
flange on output shaft housing.
3.Fit output shaft housing to main casing.
4.Apply Loctite 290 to 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.

TRANSFER BOX - LT230SE
REPAIRS 41-37
Sensor - oil temperature
$% 41.20.80
Remove
1.Lower vehicle.
2.Disconnect 2 Lucar connectors from oil
temperature sensor.
3.Remove oil temperature sensor and discard
sealing washer.
Refit
1.Clean sensor and mating face on transfer box.
2.Fit new sealing washer, position oil
temperature sensor and tighten to 42 Nm (31
lbf.ft).
3.Connect Lucar connectors to oil temperature
sensor.
4.Lower vehicle.
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 26 Nm (19 lbf.ft) .
3.Connect multiplug to harness and fit multiplug
to bracket on transfer box.
4.Lower vehicle.

TRANSFER BOX - LT230SE
41-44 OVERHAUL
14.Remove and discard oil seal from housing.
15.Remove and discard circlip retaining output
shaft bearing.
16.Support housing and drift out output shaft
bearing. 17.Remove and discard differential bearing track
and collect selective shim.
18.Remove Allen plug securing high/low selector
shaft detent spring and ball, remove spring and
ball.
19.Withdraw differential assembly together with
high/low selector shaft and fork.
20.Remove selector fork and shaft from
differential.
Note: Selector fork fitted to 03 MY onwards
illustrated.

TRANSFER BOX - LT230SE
OVERHAUL 41-49
19.Check width of high/low selector groove.
lGroove width = 16.0 to 16.1 mm (0.63 to
0.64 in).
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 MY 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 MY transfer boxes may be fitted to
pre 03 MY 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.
Reassembly
1.Lubricate all components with recommended
oil and lightly oil the differential bolt threads.

TRANSFER BOX - LT230SE
41-52 OVERHAUL
Refit
1.Clean differential components.
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.
10.Using tool LRT-41-007, fit new bearing
retaining nut and tighten to 72 Nm (53 lbf.ft).
Do not stake nut at this stage.