Discovery 2. Manual — part 556
TRANSFER BOX - LT230SE
REPAIRS
41-27
Transfer box - V8
$% 41.20.25.99
Remove
1. Remove front exhaust pipe.
SYSTEMS - V8, REPAIRS, Front pipe.
2. Drain transfer box oil.
3. Remove 8 bolts securing rear cross member
and remove cross member.
4. Remove 3 nuts securing intermediate silencer
to tail pipe.
5. Release silencer from mounting rubbers,
remove silencer and discard gasket.
6. Remove front propeller shaft.
7. Remove rear propeller shaft.
8. Remove handbrake drum retaining screw and
remove handbrake drum.
9. Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
10. Remove clevis pin and 'C' washer securing
high/low ratio selector cable to selector lever
and release cable from abutment bracket.
TRANSFER BOX - LT230SE
41-28
REPAIRS
11. Remove 2 cable ties securing cable to fuel
pipes.
12. Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
13. Remove banjo bolt securing breather pipe and
discard washers.
14. If fitted - Disconnect 2 Lucars from differential
lock switch.
15. Release and disconnect transfer box neutral
switch multiplug.
16. Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
17. Position gearbox support jack and secure
support plate to jack using 4 bolts.
18. Remove 3 bolts securing transfer box to
gearbox.
19. Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
20. Remove 2 bolts and nut securing transfer box
to gearbox case. If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
21. Position a jack to support gearbox and engine.
TRANSFER BOX - LT230SE
REPAIRS
41-29
22. Remove 4 bolts and nut securing RH mounting
to body and transfer box.
23. Remove nut securing LH mounting to body.
24. Raise gearbox and remove RH mounting.
25. With assistance, remove transfer box from
gearbox.
26. Remove input shaft oil seal.
REPAIRS, Oil seal - input shaft.
Refit
1. Fit new input shaft oil seal.
REPAIRS, Oil seal - input shaft.
2. Clean transfer box to gearbox mating faces.
3. Raise transfer box on jack and align to guide
studs LRT-41-009.
4. Clean transfer box to gearbox bolt threads.
5. Apply Loctite 290 to bolt and stud threads.
6. Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted apply Loctite 290 to threads of stud
and tighten to 45 Nm (33 lbf.ft)
7. Remove guide studs, fit and lightly tighten 3
bolts.
8. Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft.
9. Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10. Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11. Fit nut to LH mounting and tighten to 48 Nm (35
lbf.ft).
12. Remove 4 bolts securing support plate to
gearbox jack.
13. Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
14. Clean threads of bottom plate bolts.
15. Apply Loctite 290 to threads of bolts.
16. Fit 4 bolts securing bottom plate and tighten to
25 Nm (18 lbf.ft).
17. Using new washers position breather pipe and
tighten banjo bolt.
18. Connect multiplug to transfer box neutral switch
and secure harness.
19. If fitted - Connect Lucars to differential lock
switch.
20. Connect multiplug and Lucars to reverse lamp
switch and oil temperature sensor.
21. Position high/low ratio selector cable and
secure with 'C' washer and clevis pin.
22. Secure cable to fuel pipes with new cable ties.
23. Clean handbrake back plate and mating face.
24. Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
25. Clean handbrake drum.
26. Fit handbrake drum and tighten retaining
screw.
27. Fit front propeller shaft.
28. Fit rear propeller shaft.
29. Clean exhaust silencer and tail pipe mating
faces.
30. Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
31. Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32. Refill transfer box with oil.
33. Fit front exhaust pipe.
TRANSFER BOX - LT230SE
41-30
REPAIRS
Gasket - rear cover plate
$% 41.20.30
Remove
1. Mark rear cover to bearing housing for
assembly purposes.
2. Note fitted position of stud nut, remove stud nut
and 5 bolts securing rear cover.
3. Carefully release rear cover from bearing
housing.
Refit
1. Clean rear cover, mating face on bearing
housing and sealant from stud/bolt threads.
2. Apply sealant Part No. STC 3254 to rear cover
mating face.
3. Align reference marks and position rear cover.
4. Apply Loctite 290 to stud/bolt threads, fit rear
cover plate stud nut and bolts and tighten to 25
Nm (18 lbf.ft).
5. Top-up transfer box oil.
Switch - differential lock - Up to 03 MY
$% 41.20.34
Remove
1. Remove front propeller shaft.
2. Disconnect 2 Lucars from switch.
3. Remove switch and remove nut from switch.
Refit
1. Clean switch and gearbox face.
2. Fit nut to switch 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).
3. Apply Hylomar PL 32 sealant to switch thread.
4. Position switch into front output housing until
nut bottoms out on housing.
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