Discovery 2. Manual — part 135

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OVERHAUL

41-43

OVERHAUL

Intermediate gear assembly

$% 41.20.10

Disassembly

1. Remove and discard 10 bolts securing bottom

cover, remove cover.

2. Remove 7 bolts securing differential lock

selector side cover.

3. Remove side cover.

4. Release staking from intermediate shaft nut,

remove and discard nut.

5. Remove bolt securing intermediate shaft

retaining plate, remove plate.

6. Remove intermediate shaft and discard 2 'O'

rings.

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41-44

OVERHAUL

7. Remove intermediate gear assembly and

collect bearings and selective spacer.

8. Secure gear assembly in a soft jawed vice and

using a suitable drift, remove and discard
bearing tracks.

9. Up to 03 Model Year:Remove and discard

circlips.

Reassembly

1. Up to 03 Model Year:Clean gears, bearings,

circlips, shaft and mating faces of front output
housing, side and bottom covers.

Note: Intermediate gear cluster and bearing
assemblies fitted to 03 Model Year boxes may
be fitted as replacements to pre 03 Model Year
boxes.

2. 03 Model Year onwards:Clean gears,

bearings and shaft.

3. Up to 03 Model Year: Fit new circlips and

using tools LRT-99-003 and LRT-41-006 fit
bearing tracks to intermediate gear, ensuring
that the bearing tracks are fully seated against
the circlips.

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41-45

4. 03 Model Year onwards: Using tools LRT-99-

003 and LRT-41-006, fit bearing tracks to
intermediate gears ensuring that tracks are fully
seated against shoulders in gears.

5. Using a micrometer, measure the width of each

bearing inner track.

6. Record each reading as measurement 'A' and

'B', both measurements should fall within the
range of 21.95 to 22.00 mm (0.864 to 0.866 in).

7. Fit inner bearing track 'A' onto tool LRT-41-017

and position intermediate gear cluster onto
bearing 'A'.

8. Fit inner bearing track 'B' to intermediate gear,

apply finger pressure to bearing inner track
and rotate intermediate gear 5 to 10 turns to
settle in bearing rollers.

9. Attach a DTI to base of tool LRT-41-017 , zero

gauge on top of tool post and take 2
measurements at 180

°

of the step height

between the top of the tool post and the
bearing inner track. Take an average of the two
readings and record this as measurement 'C'.
Measurement 'C' should be in the range of 0.15
to 0.64 mm (0.006 to 0.025 in).

10. Using the formula 103.554 mm (4.0769 in) -'A'-

'B'-'C', calculate the length of bearing spacer
required. From the result of the calculation
round DOWN to the nearest length of spacer
available to give a correct bearing pre-load of
0.005 mm (0.002 in). 40 spacers are
available ranging in length from 58.325 mm
(2.296 in) to 59.300 mm (2.335 in) rising in
increments of 0.025 mm (0.001 in).

11. Remove intermediate gear assembly from tool

LRT-41-017.

12. Lubricate and fit bearings and selected spacer

to intermediate gear.

13. Position tool LRT-41-004 through bearings

and spacer.

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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.