Discovery 2. Manual — part 130

TRANSFER BOX - LT230SE

REPAIRS

41-23

REPAIRS

Bottom cover - transfer box

$% 41.20.06

Remove

1. Raise vehicle on ramp.
2. Drain transfer box oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

3. Remove 8 bolts securing cross member to

chassis and remove cross member.

4. Remove 10 bolts securing bottom cover to

transfer box and remove cover.

Refit

1. Clean bottom plate and mating face on transfer

box.

2. Clean bolt threads.
3. Apply sealant, Part No. STC 4600 to bottom

plate sealing face.

4. Apply sealant, Part No. STC 50552 to bolt

threads.

5. Position bottom plate and tighten bolts to 25

Nm (18 lbf.ft).

6. Position cross member to chassis and tighten

bolts to 26 Nm (19 lbf.ft).

7. Fill transfer box with oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

8. Lower vehicle on ramp.

TRANSFER BOX - LT230SE

41-24

REPAIRS

Cable - selector - differential lock

$% 41.20.12

Remove

1. Remove centre console.

+

INTERIOR TRIM COMPONENTS,

REPAIRS, Console - centre - automatic
models.

2. Remove 4 bolts securing transfer gearbox high/

low selector lever to transmission tunnel.

3. Remove front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

4. Models fitted with high/low shift interlock

solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.

5. Models fitted with high/low shift interlock

solenoid: Remove sleeve retaining rings and
remove sleeve from high/low select cable.

6. Release and remove clevis pin and 'C' clip

securing transfer gearbox high/low selector
cable to transfer gearbox high/low selector
lever. Position the cable aside.

7. Release and remove clevis pin securing

differential lock selector cable to transfer
gearbox.

8. Loosen locknuts securing differential lock

selector cable to differential lock selector cable
abutment bracket.

9. Release and remove differential lock selector

cable from differential lock selector cable
abutment bracket.

10. Remove transfer gearbox high/low selector

lever assembly from transmission tunnel.

11. Release and remove clevis pin and 'C' clip

securing differential lock selector cable to
differential lock selector lever. Remove the
differential lock selector cable.

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.

TRANSFER BOX - LT230SE

41-26

REPAIRS

9. Remove handbrake drum retaining screw and

remove drum.

10. Remove 4 bolts from handbrake back plate,

release back plate and tie aside.

11. Models fitted with high/low shift interlock

solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.

12. Models fitted with high/low shift interlock

solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.

13. If fitted: Release and remove clevis pin

securing differential lock selector cable to
transfer gearbox.

14. If fitted: Loosen locknuts securing differential

lock selector cable to differential lock selector
cable abutment bracket.

15. If fitted: Release and remove differential lock

selector cable from differential lock selector
cable abutment bracket.

16. Remove clevis pin securing high/low ratio

selector cable to selector lever, remove 'C' clip
and release outer cable from abutment bracket.

17. Up to 03 Model Year - if fitted: Disconnect 2

Lucars from differential lock switch and
multiplugs from high/low ratio switch and
neutral sensor.

18. Disconnect multiplug from reverse light switch.