Discovery 2. Manual — part 136

TRANSFER BOX - LT230SE

OVERHAUL

41-47

3. Note position of longest bolt and remove 8 bolts

securing front output shaft housing to main
casing and remove housing.

Note: Carry out the following operations if
differential lock is fitted.

4. Differential lock fitted: Remove 3 bolts

securing differential lock selector housing and
remove housing.

5. Differential lock fitted: Remove and discard

'O' rings from selector housing.

6. Up to 03 Model Year: Remove Allen plug and

remove differential lock detent spring and ball.

7. Up to 03 Model Year: Remove differential lock

warning lamp switch and locknut.

8. 03 Model Year onwards - differential lock

fitted: Remove 2 differential lock warning lamp
switches and sealing washers.

9. 03 Model Year onwards - differential lock

fitted: Note position of longest bolt and remove
8 bolts securing front output housing to main
casing and remove housing.

10. 03 Model Year onwards - differential lock

fitted: Remove 3 bolts securing differential lock
selector housing and bracket, remove bracket
and housing.

11. 03 Model Year onwards - differential lock

fitted: Remove and discard 'O' rings from
selector housing.

12. 03 Model Year onwards - differential lock

fitted: Remove detent plug, recover spring and
ball.

13. All transfer boxes fitted with differential

lock: Compress differential lock selector fork
spring and remove retaining clips from each
end of spring.

14. All transfer boxes fitted with differential

lock: Withdraw differential lock selector shaft
from front output housing, recover spring and
remove selector fork.

TRANSFER BOX - LT230SE

41-48

OVERHAUL

15. Position tool LRT-51-003 to output shaft drive

flange, remove and discard nut, steel and felt
washers; remove output shaft drive flange.

16. Using a copper mallet, drive output shaft from

housing, recover bearing spacer.

17. If fitted: Noting its fitted position, remove dog

clutch from output shaft.

18. Remove and discard oil seal from housing.
19. Remove and discard circlip retaining output

shaft bearing.

20. Support housing and drift out output shaft

bearing.

21. Remove and discard differential bearing track

and collect selective shim.

TRANSFER BOX - LT230SE

OVERHAUL

41-49

22. Remove plug securing high/low selector shaft

detent spring and ball, remove spring and ball.

23. Withdraw differential assembly together with

high/low selector shaft and fork.

24. Remove selector fork and shaft from

differential.

Note: Selector fork fitted to 03 MY onwards
illustrated.

25. Note position of shoulder bolt, remove 6 bolts

and remove rear output shaft housing.

26. Remove rear bearing track from main casing.

27. Secure differential in a soft jawed vice.
28. Release staking from bearing retaining nut.
29. Using tool LRT-41-007 remove and discard

bearing retaining nut.

TRANSFER BOX - LT230SE

41-50

OVERHAUL

30. Position tool LRT-99-002 to vice.
31. Position tool LRT-41-001 around rear

differential bearing, position differential to tool
LRT-99-002 and press off bearing.

32. Remove high range gear and bush.
33. Make suitable alignment marks between high/

low selector sleeve and hub, remove selector
sleeve.