Discovery 2. Manual — part 557

TRANSFER BOX - LT230SE

REPAIRS

41-31

5. Tighten nut securing differential lock switch to

11 Nm (8 lbf.ft)

6. Connect Lucars to switch.
7. Fit front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

Cable - high/low selector

$% 41.20.43

Remove

1. Raise vehicle on a ramp.

2. Using a suitable crowsfoot spanner, remove

lock nut and washer securing outer cable to
abutment bracket.

3. Remove clevis pin securing inner cable to

transfer box lever and release cable from
abutment bracket.

4. Release 'C' clip securing outer cable to high/

low lever abutment bracket.

5. Remove clevis pin securing inner cable to high/

low lever.

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.