Discovery 2. Manual — part 132

TRANSFER BOX - LT230SE

REPAIRS

41-31

21. 03 Model Year onwards - if fitted: Release

and disconnect both differential lock warning
lamp switch multiplugs from main harness.

22. Remove 4 bolts from transfer box bottom plate,

position support plate LRT-99-010 to transfer
box and tighten bolts.

23. Position gearbox support jack and secure

support plate to jack using 4 bolts.

24. Remove 3 bolts securing transfer box to

gearbox.

25. Fit 3 guide studs LRT-41-009 through transfer

box bolt holes to support it during removal.

26. Remove 2 bolts and nut securing transfer box

to gearbox case.

CAUTION: If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.

27. Position a jack to support gearbox and engine.

28. Remove 4 bolts and nut securing RH mounting

to body and transfer box.

29. Remove nut securing LH mounting to body.
30. Raise gearbox and remove RH mounting.
31. With assistance, remove transfer box from

gearbox.

32. Remove input shaft oil seal.

+

TRANSFER BOX - LT230SE,

REPAIRS, Oil seal - input shaft.

TRANSFER BOX - LT230SE

41-32

REPAIRS

Refit

1. Fit new input shaft oil seal.

+

TRANSFER BOX - LT230SE,

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 sealant, Part No. STC 50552 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 sealant, Part No. STC 50552 to
stud threads 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 sealant, Part No. STC 50552 to threads

of 4 bottom plate 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. Up to 03 Model Year - if fitted : Connect

Lucars to differential lock switch and multiplugs
to high/low ratio switch and neutral sensor.

20. 03 Model Year onwards - if fitted: Connect

differential lock warning lamp multiplugs,
secure harness.

21. Connect multiplug to reverse lamp switch.
22. If fitted: Connect Lucars to oil temperature

switch.

23. Position high/low ratio selector cable and

secure with 'C' clip and clevis pin.

24. If fitted: Position differential lock selector cable

to differential lock selector cable abutment
bracket and tighten locknuts sufficiently to
retain cable.

25. If fitted: Fit differential lock selector cable to

transfer gearbox and secure with clevis pin.

26. If fitted: Adjust differential lock selector cable.

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TRANSFER BOX - LT230SE,

ADJUSTMENTS, Cable - selector -
differential lock - adjust.

27. Models fitted with high/low shift interlock

solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness; secure sleeve.

28. Models fitted with high/low shift interlock

solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.

29. Secure cable to fuel pipes with new cable ties.
30. Clean handbrake back plate and mating face.
31. Position handbrake back plate, fit bolts and

tighten to 75 Nm (55 lbf.ft).

32. Clean handbrake drum.
33. Fit handbrake drum and tighten retaining

screw.

34. Fit front propeller shaft.

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PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

35. Fit rear propeller shaft.

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PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

36. Clean exhaust silencer and tail pipe mating

faces.

37. Position silencer and secure on mountings,

using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).

38. Position rear cross member, fit bolts and

tighten to 26 Nm (19 lbf.ft).

39. Refill transfer box with oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

40. Fit front exhaust pipe.

+

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Front pipe.

TRANSFER BOX - LT230SE

REPAIRS

41-33

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 4600 to rear cover

mating face.

3. Align reference marks and position rear cover.
4. Apply sealant, Part No. STC 50552 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.

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MAINTENANCE, PROCEDURES,

Transfer box.

TRANSFER BOX - LT230SE

41-34

REPAIRS

Switch - differential lock - Up to 03 MY

$% 41.20.34

Remove

1. Remove front propeller shaft.

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PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

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 sealant, Part No. STC 50552 to switch

thread.

4. Position switch into front output housing until

nut bottoms out on housing.

5. Tighten nut securing differential lock switch to

11 Nm (8 lbf.ft)

6. Connect Lucars to switch.
7. Fit front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.