Discovery 2. Manual — part 137

TRANSFER BOX - LT230SE

OVERHAUL

41-51

34. Using a suitable press and thrust button LRT-

41-001 remove high/low hub and low range
gear.

35. Position tool LRT-41-002 around front

differential bearing and tool LRT-41-001 thrust
button to differential shaft and press off
bearing.

Disassembly

1. Secure rear half of differential carrier in a soft

jawed vice.

2. Make suitable alignment marks between front

and rear halves of differential carrier.

3. Remove 8 bolts securing front half of carrier to

rear and separate both halves of carrier.

4. Suitably identify front sun gear to front half of

carrier, then remove sun gear.

5. Remove and discard thrust washer.
6. Suitably identify each planet gear to its shaft

and fitted position of each cross shaft to rear
half of carrier

7. Remove retaining ring.
8. Remove planet gears and cross shafts, remove

and discard dished thrust washers.

9. Suitably identify rear sun gear to rear half of

carrier, then remove sun gear.

10. Remove and discard thrust washer.

TRANSFER BOX - LT230SE

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OVERHAUL

Inspect

1. Check mating surfaces of cross shaft and

housing bore for wear.

2. Check core plug in housing for signs of leakage

or corrosion ; apply sealant, Part No. STC 3811
to replacement plug.

3. Measuring across widest portion of finger,

check high/low selector finger for wear.

l

Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in).

4. Check bearing track recesses in housing for

damage, rectify or replace housing as
necessary.

5. If fitted: Carry out inspection of differential

lock components using following procedures.

6. Check differential lock selector shaft and

housing bore for wear.

7. Measuring across the widest portion, check

differential lock finger for wear.

l

Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in).

Note: Differential lock selector shaft fitted to 03

Model Year onwards illustrated.

8. Check differential lock selector finger groove in

selector shaft.

l

Groove width = 16.0 to 16.1 mm (0.63 to
0.64 in).

Differential lock selector shaft fitted to 03 Model Year

onwards illustrated.

9. Check detent grooves in differential lock

selector shaft for wear.

10. Check differential lock detent ball for flat spots

and check detent spring for distortion.

TRANSFER BOX - LT230SE

OVERHAUL

41-53

11. Check differential lock selector fork for cracks

and wear.

12. Check selector fork finger width.

l

Finger width = 7.92 to 7.97 mm (0.311 to
0.313 in).

13. Check differential lock selector fork clips for

wear and damage. Check spring for distortion
and free length.

l

Spring free length = 84.58 mm (3.33 in).

14. Check dog clutch internal teeth and grooves

and teeth on output shaft for wear and
damage. Check selector fork groove width.

l

Groove width = 8.05 to 8.20 mm (0.32 to
0.33 in).

15. Carry out the following inspection procedures

for all transfer boxes.

16. Check threads and splines of output shaft for

damage and wear. Check dog clutch teeth on
shaft for wear and damage.

17. 03 Model Year onwards: Compress high/low

selector fork spring and remove retaining clips
from each end of spring, remove high/low
selector shaft.

High/low selector shaft fitted to pre 03 Model Year

illustrated.

18. Check detent grooves in high/low selector shaft

for wear. Do not remove fork from shaft
unless either component is being renewed.
If fork is removed from shaft, coat the
threads of the set screw with sealant, Part
No. STC 50552 prior to assembling.

19. Check width of high/low selector groove.

l

Groove width = 16.0 to 16.1 mm (0.63 to
0.64 in).

TRANSFER BOX - LT230SE

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OVERHAUL

20. Check high/low selector fork for cracks and

wear. Check selector fork finger width.

l

Finger width = 7.37 to 7.47 mm (0.290 to
0.294 in).

21. 03 Model Year onwards: Check high/low

selector fork clips for wear and damage. Check
spring for distortion, check free length of spring:

l

Spring free length = 75 mm (2.95 in)

Note: High/low selector shaft, fork and spring
fitted to 03 Model Year transfer boxes may be
fitted to pre 03 Model Year boxes as an
assembly.

22. Check differential sun and planet gears for

wear, cracks and chipping of teeth.

23. Check cross shafts and recesses in both halves

of differential carrier for damage and
wear.Ensure planet gears are retained with
their respective shafts.

24. Check retaining ring for distortion.
25. Check differential splines for wear and

damage.

26. Check high/low hub for cracks, chipping and

uneven wear. Check width of selector fork
groove.

l

Groove width = 7.5 to 7.6 mm (0.295 to 0.30
in).

27. Check splines and teeth on high/low selector

sleeve for uneven wear, cracks, damage and
chipping.

28. Check teeth of high and low range gears for

cracks, chipping and uneven wear.

29. Check high range gear bush for wear and

damage.