Discovery 2. Manual — part 563

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

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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).