Discovery 2. Manual — part 560

TRANSFER BOX - LT230SE

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41-43

4. Remove 3 bolts securing differential lock

selector housing and remove housing.

5. Remove and discard 'O' ring from selector

housing.

6. Remove Allen plug and remove detent spring

and ball.

7. Remove differential lock 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.

8. 03 MY onwards: Remove differential lock

warning lamp switch from end of front output
shaft housing, discard sealing washer.

9. Compress differential lock selector fork spring

and remove retaining clips from each end of
spring.

10. Withdraw differential lock selector shaft from

front output housing, recover spring and
remove selector fork.

Note: Carry out the following operations for all
transfer boxes.

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

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

12. Using a copper mallet, drive output shaft from

housing, recover bearing spacer.

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

clutch from output shaft.

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OVERHAUL

14. Remove and discard oil seal from housing.
15. Remove and discard circlip retaining output

shaft bearing.

16. Support housing and drift out output shaft

bearing.

17. Remove and discard differential bearing track

and collect selective shim.

18. Remove Allen plug securing high/low selector

shaft detent spring and ball, remove spring and
ball.

19. Withdraw differential assembly together with

high/low selector shaft and fork.

20. Remove selector fork and shaft from

differential.

Note: Selector fork fitted to 03 MY onwards
illustrated.

TRANSFER BOX - LT230SE

OVERHAUL

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21. Note position of shoulder bolt, remove 6 bolts

and remove rear output shaft housing.

22. Remove rear bearing track from main casing.

23. Secure differential in a soft jawed vice.
24. Release staking from bearing retaining nut.
25. Using tool LRT-41-007 remove and discard

bearing retaining nut.

26. Position tool LRT-99-002 to vice.
27. Position tool LRT-41-001 around rear

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

28. Remove high range gear and bush.

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29. Make suitable alignment marks between high/

low selector sleeve and hub, remove selector
sleeve.

30. Using a suitable press and thrust button LRT-

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

31. 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.