Discovery 2. Manual — part 564

TRANSFER BOX - LT230SE

OVERHAUL

41-59

21. Clean threads of differential lock warning lamp

switch(es).

22. Up to 03 MY: Fit nut to switch head 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).

23. Apply Hylomar PL 32 sealant to threads of

differential warning lamp switch(es).

24. Up to 03 MY: Position switch into front output

housing until nut bottoms out on housing,
tighten nut to 11 Nm (8 lbf.ft).

25. 03 MY onwards: Fit new sealing washers to

switches, fir switches to front output housing
and tighten to 25 Nm (18 lbf.ft).

26. Operate differential lock selector lever and

check that detent ball can be felt to positively
engage/disengage with grooves in shaft.
Screw plug in or out until setting is correct.

27. Fit output flange, new felt and steel washers

and new retaining nut.

28. Using tool LRT-51-003 to restrain flange,

tighten output flange nut to 162 Nm (119 lbf.ft).

TRANSFER BOX - LT230SE

41-60

OVERHAUL

Input gear/bearing

$% 41.20.60

Disassembly

1. Make alignment marks between cover plate/

bearing housing and main casing.

2. Remove 5 bolts and stud nut securing cover/

bearing housing to main casing. Remove cover
and bearing housing.

3. Remove input gear assembly.

4. Remove and discard oil seal from main casing.

5. Drift out bearing track from main casing.

TRANSFER BOX - LT230SE

OVERHAUL

41-61

6. Drift out bearing track from housing and collect

selective shim.

7. Position tool LRT-99-002 to vice.
8. Assemble tool LRT-41-003 to bearing, position

input gear to hand press and remove bearing.

9. Repeat procedure for remaining bearing.

Reassembly

1. Clean input gear, cover/bearing housing and

main casing.

2. Using tool LRT-99-002 and LRT-41-003 fit

new bearings to input gear.

3. Using a suitable mandrel, fit bearing track to

main casing.

4. Fit a 3.15 mm (0.12 in) thick shim to bearing

housing and using a suitable mandrel fit
bearing track to housing.

5. Position input gear to main casing.

6. Fit bearing housing, ensuring reference marks

are aligned, secure bearing housing with 2
bolts and tighten to 25 Nm (18 lbf.ft).

TRANSFER BOX - LT230SE

41-62

OVERHAUL

7. Position dial gauge with stylus contacting input

gear, push input gear rearwards and zero
gauge.

8. Push input gear forwards and note gauge

reading.

9. Calculate thickness of shim required using the

formula - A+B+C=D where:

l

A= Thickness of installed shim - 3.15 mm
(0.12 in)

l

B= Recorded end-float.

l

C= Required pre-load - 0.05 mm (0.002 in).

l

D= Thickness of shim required.

10. If an alternative shim is required to establish

correct pre-load, fit an alternative shim. Shims
are available from 3.15 to 4.00 mm (0.12 to
0.16 in) thickness, in increments of 0.05 mm
(0.002 in).

11. Remove 2 bolts, remove bearing housing and

input gear.

12. Lubricate input gear and bearings with

recommended oil.

13. Position input gear into main casing.
14. Apply sealant, Part No. STC 3254 to bearing

housing and cover.

15. Position bearing housing/cover, align reference

marks and tighten by diagonal selection to 45
Nm (33 lbf.ft).

16. Using tool LRT-37-014 fit new input shaft oil

seal.

Low gear - differential

$% 41.20.62

Disassembly

1. Remove differential.

+

TRANSFER BOX - LT230SE,

OVERHAUL, Dog clutch - differential lock.

2. Secure differential in a soft jawed vice.

3. Release staking from bearing retaining nut.
4. Using tool LRT-41-007 remove and discard

bearing retaining nut.

5. Position tool LRT-99-002. to a vice.
6. Position tool LRT-41-001 around rear

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