differential LAND ROVER DISCOVERY 2002 Repair Manual

TRANSFER BOX - LT230SE
OVERHAUL 41-53
11.Using feeler gauges, determine clearance
between low range gear and high/low hub:
lClearance = 0.05 to 0.15 mm (0.002 to
0.006 in).
12.If clearance is not as specified, fit a new low
range gear and high/low hub and re-check.
13.Using feeler gauges, determine clearance
between high range gear and high/low hub:
lClearance = 0.05 to 0.15 mm (0.002 to
0.006 in).
14.If clearance is not as specified, fit new high
range gear and high/low hub and re-check. 15.Using a suitable drift, stake collar of nut into
differential shaft recess.
16.Using LRT-51-009, fit new rear bearing track
into main casing.
17.Using a straight edge and feeler gauges, check
that bearing track is recessed 1 mm (0.04 in)
below outer face of main casing.
18.Apply sealant, Part No. STC 3254 to rear
output shaft housing face.
19.Position housing to main casing.
20.Apply Loctite 290 to bolt threads fit housing to
main case bolts and tighten by diagonal
selection to 45 Nm (33 lbf.ft).
21.03 MY only: Fit high/low selector fork and
spring to high/low selector shaft, fit retaining
clips.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
22.Position high/low selector shaft and fork to
differential ensuring that fingers of selector fork
are located in selector sleeve.
23.Position differential assembly into main casing
ensuring that splines of rear output shaft are
engaged in differential.
24.Position new differential front bearing track
ensuring that track is seated squarely.

TRANSFER BOX - LT230SE
41-54 OVERHAUL
25.Position tool LRT-41-014/3 onto main casing.
26.Screw tool LRT-41-014/4 into tapped hole in
main casing and attach suitable DTI to pillar.
27.Position stylus of gauge to setting block LRT-
41-014/3 and zero gauge.
28.Position stylus onto front bearing outer track
and record reading. 29.Taking care not to disturb bearing, position
stylus on opposite side of bearing track and
record reading.
30.Obtain average of the 2 readings and record
figure.
31.Position depth block tool LRT-41-014/2 and
cross bar tool LRT-41-014/1 to front output
housing.
32.Position DTI to tool LRT-41-014/1 cross bar
and zero DTI on depth block.
33.Position DTI to cross bar and record reading
obtained.
34. Using the formula: 3.05 mm (0.120 in)+B-
A=D where: B=Height difference recorded
between depth block and cross bar.
A=Average of readings to differential front
bearing outer track. D=Thickness of shim
required to give differential bearing pre-load of
0.05 mm (0.002 in).
35.From the resultant figure obtained, select
appropriate thickness shim from the range
available.
36.Shims are available from 2.00 to 3.25 mm
(0.08 to 0.13 in) thickness, rising in increments
of 0.05 mm (0.002 in).

TRANSFER BOX - LT230SE
OVERHAUL 41-55
37.Heat the front output housing to 100°C (210°F)
and fit new output shaft bearing using tool
LRT-41-011.
38.Allow housing to air cool.
39.Fit new bearing retaining circlip ensuring that
circlip is fully seated.
40.Using tool LRT-41-012, fit new output shaft oil
seal. Check that oil seal is just contacting
circlip. 41.Position selected shim in front output housing
and using tool LRT-54-003, fit new differential
front bearing track.
42.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
43. If fitted: Fit dog clutch with flange on clutch
facing towards splined end.
44.Using a copper mallet, drive output shaft into
bearing.
Note: Carry out the following operations for
transfer boxes fitted with differential lock.
45.Compress differential lock selector spring and
fit selector fork.
46.Position selector fork to groove in dog clutch.
47.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face.

TRANSFER BOX - LT230SE
41-56 OVERHAUL
48.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess of clips.
49.Fit detent ball and spring.
50.Apply Loctite 290 to threads of detent plug.
51.Fit and tighten detent plug, then loosen 2
complete turns.
52.Fit new 'O' ring to differential lock selector
housing.
53.Fit selector housing, ensure selector finger is
located in shaft recess.
54.Apply Loctite 290 to threads of bolts, and
tighten selector housing bolts to 25 Nm (18
lbf.ft).
55.Clean threads of differential lock warning lamp
switch(es).
56.Up to 03 MY: Fit nut to switch head 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).
57.Apply Hylomar PL 32 sealant to threads of
differential warning lamp switch(es).
58.Up to 03 MY: Position switch into front output
housing until nut bottoms out on housing;
tighten nut to 11 Nm (8 lbf.ft)
59.03 MY onwards: Fit new sealing washers to
switches, fit switches in front output housing
and tighten to 25Nm (18 lbf.ft).
Note: Carry out the following operations for all
transfer boxes.
60.Apply sealant, Part No. STC 3254 to front
output shaft housing. 61.Position housing ensuring that output shaft and
dog clutch splines - if fitted are correctly
engaged.
62.Clean output housing bolt threads.
63.Apply Loctite 290 to threads of bolts.
64.Fit output shaft housing bolts and tighten in a
diagonal sequence to 45 Nm (33 lbf.ft).
65.Fit output flange, new felt washer, steel washer
and new retaining nut.
66.Using tool LRT-51-003 to restrain flange,
tighten output flange nut to 162 Nm (119 lbf.ft).
67. If fitted - Operate differential lock selector
lever and check that detent ball can be felt to
positively engage/disengage with grooves in
shaft. Screw plug in or out until setting is
correct.
68.Fit high/low selector shaft detent ball and
spring.
69.Apply Loctite 290 sealant to threads of high/low
selector shaft detent plug.
70.Fit and tighten plug, then loosen 2 complete
turns.
71. Operate high/low selector lever and check that
detent ball can be felt to positively engage/
disengage with grooves in shaft. Screw plug in
or out until setting is correct.
72.Fit intermediate gear cluster.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Intermediate gear assembly.

TRANSFER BOX - LT230SE
OVERHAUL 41-57
Dog clutch - differential lock
$% 41.20.23
Disassembly
1.Remove 6 bolts securing high/low cross shaft
housing to front output shaft housing and
remove housing.
2.Note position of longest bolt and remove 8
bolts securing front output shaft housing to
main casing and remove housing.
3.Remove 3 bolts securing differential lock
selector housing and remove housing. 4.Remove and discard 'O' ring from selector
housing.
5.Remove differential warning lamp switch and
locknut.
Note: Locknut is only fitted to switches up to 03
MY, a modified switch and sealing washer is
fitted from 03 MY onwards..
6.03 MY onwards: Remove differential lock
warning lamp switch from end of front output
shaft housing, discard sealing washer.
7.Remove Allen plug and remove detent spring
and ball.
8.Compress differential lock selector fork spring
and remove retaining clips from each end of
spring.
9.Withdraw differential lock selector shaft from
front output housing, recover spring and
remove selector fork.

TRANSFER BOX - LT230SE
41-58 OVERHAUL
10.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut.
11.Remove and discard steel and felt washers.
Remove output shaft drive flange.
12.Using a copper mallet, drive output shaft from
housing.
13.Noting its fitted position, remove bearing
spacer from output shaft.
14.Noting its fitted position, remove dog clutch
from output shaft.
15.Remove and discard oil seal from housing. Reassembly
1.Clean differential lock components.
2.Lubricate components with gearbox oil.
3.Using tool LRT-41-012, fit new output shaft oil
seal.
4.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
5.Fit dog clutch with flange on clutch facing
towards splined end.
6.Using a copper mallet, drive output shaft into
bearing.
7.Compress differential lock selector spring and
fit selector fork.
8.Position selector fork to groove in dog clutch.
9.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face.
10.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
11.Fit detent ball and spring.
12.Apply Loctite 290 to threads of detent plug.
13.Fit and tighten detent plug, then unscrew 2
complete turns.
14.Fit new 'O' ring to differential lock selector
housing.
15.Fit selector housing, ensure selector finger is
located in shaft recess.
16.Apply Loctite 290 to threads of bolts and tighten
selector housing bolts to 25 Nm (18 lbf.ft).
17.Apply sealant, Part No. STC 3254 to front
output shaft housing.
18.Position housing ensuring that output shaft and
dog clutch splines are correctly engaged.
19.Apply Loctite 290 to threads of bolts.
20.Fit front output shaft housing bolts and tighten
in a diagonal sequence to 45 Nm (33 lbf.ft).

TRANSFER BOX - LT230SE
OVERHAUL 41-59
21.Clean threads of differential lock warning lamp
switch(es).
22.Up to 03 MY: Fit nut to switch head 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).
23.Apply Hylomar PL 32 sealant to threads of
differential warning lamp switch(es).
24.Up to 03 MY: Position switch into front output
housing until nut bottoms out on housing,
tighten nut to 11 Nm (8 lbf.ft).
25.03 MY onwards: Fit new sealing washers to
switches, fir switches to front output housing
and tighten to 25 Nm (18 lbf.ft).
26.Operate differential lock selector lever and
check that detent ball can be felt to positively
engage/disengage with grooves in shaft.
Screw plug in or out until setting is correct.27.Fit output flange, new felt and steel washers
and new retaining nut.
28.Using tool LRT-51-003 to restrain flange,
tighten output flange nut to 162 Nm (119 lbf.ft).

TRANSFER BOX - LT230SE
41-62 OVERHAUL
7.Position dial gauge with stylus contacting input
gear, push input gear rearwards and zero
gauge.
8.Push input gear forwards and note gauge
reading.
9.Calculate thickness of shim required using the
formula - A+B+C=D where:
lA= Thickness of installed shim - 3.15 mm
(0.12 in)
lB= Recorded end-float.
lC= Required pre-load - 0.05 mm (0.002 in).
lD= Thickness of shim required.
10.If an alternative shim is required to establish
correct pre-load, fit an alternative shim. Shims
are available from 3.15 to 4.00 mm (0.12 to
0.16 in) thickness, in increments of 0.05 mm
(0.002 in).
11.Remove 2 bolts, remove bearing housing and
input gear.
12.Lubricate input gear and bearings with
recommended oil.
13.Position input gear into main casing.
14.Apply sealant, Part No. STC 3254 to bearing
housing and cover.
15.Position bearing housing/cover, align reference
marks and tighten by diagonal selection to 45
Nm (33 lbf.ft).
16.Using tool LRT-37-014 fit new input shaft oil
seal.
Low gear - differential
$% 41.20.62
Disassembly
1.Remove differential.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Dog clutch - differential lock.
2.Secure differential in a soft jawed vice.
3.Release staking from bearing retaining nut.
4.Using tool LRT-41-007 remove and discard
bearing retaining nut.
5.Position tool LRT-99-002. to a vice.
6.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.

TRANSFER BOX - LT230SE
OVERHAUL 41-63
7.Remove high range gear and bush.
8.Make suitable alignment marks between high/
low selector sleeve and hub, remove selector
sleeve. 9.Using a suitable press and thrust button LRT-
41-001remove high/low hub and low range
gear.
Reassembly
1.Clean differential components.
2.Lubricate components with gearbox oil.
3.Fit differential in soft jawed vice, and fit low
range gear with dog teeth facing uppermost.
4.Fit high/low hub ensuring that machined
groove on hub teeth faces towards low range
gear.
5.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
6.Fit bush to high range gear ensuring collar is
uppermost.
7.Fit high range gear and bush onto shaft.

TRANSFER BOX - LT230SE
41-64 OVERHAUL
8.Fit rear bearing using tool LRT-41-008.
9.Fit new bearing retaining nut and using tool
LRT-41-007, tighten to 72 Nm (53 lbf.ft).
10.Using a suitable drift, stake collar of nut into
differential shaft recess.
11.Fit high/low selector shaft detent ball and
spring.
12.Apply Loctite 290 sealant to threads of detent
plug.
13.Fit and tighten plug, then loosen 2 complete
turns.
14.Fit differential.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Differential assembly.