Discovery 2. Manual — part 134

TRANSFER BOX - LT230SE

REPAIRS

41-39

Refit

1. Clean seal mating faces.

2. Fit new seal using tool LRT-41-012.

CAUTION: Oil seal must be fitted dry.

3. Position drive flange, fit new felt and steel

washers.

4. Position tool LRT-51-003 and tighten new

drive flange nut to 148 Nm (109 lbf.ft).

5. Position handbrake drum and tighten screw.
6. Tighten brake shoe adjuster bolt to 25 Nm (18

lbf.ft) then loosen one and a half turns.

7. Check that brake drum is free to rotate.
8. Fit propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

9. Top-up transfer box oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

Gasket - rear output shaft housing

$% 41.20.55

Remove

1. Drain transfer gearbox oil.

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MAINTENANCE, PROCEDURES,

Transfer box.

2. Remove rear output shaft seal.

+

TRANSFER BOX - LT230SE,

REPAIRS, Seal - rear output shaft.

3. Mark output shaft housing to main casing for

assembly purposes.

4. Note position of shoulder bolt, remove 6 bolts

securing housing to main casing.

Refit

1. Clean output shaft housing, mating face on

main casing and sealant from bolt threads.

2. Apply sealant, Part No. STC 4600 to mating

flange on output shaft housing.

3. Fit output shaft housing to main casing.
4. Apply sealant, Part No. STC 50552 to output

shaft housing bolt threads.

5. Fit output shaft housing bolts and tighten by

diagonal selection to 45 Nm (33 lbf.ft).

6. Fit rear output shaft seal.

+

TRANSFER BOX - LT230SE,

REPAIRS, Seal - rear output shaft.

7. Fill transfer gearbox with oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

TRANSFER BOX - LT230SE

41-40

REPAIRS

Solenoid - interlock - Up to 03 MY

$% 41.20.63

Remove

1. Raise vehicle on ramp.
2. Disconnect multiplug from interlock solenoid.
3. Release multiplug retainer from mounting plate

on transfer box.

4. Remove 4 bolts securing solenoid cover,

remove cover and Belleville washer.

5. Remove solenoid.

Refit

1. Clean solenoid cover and mating face.
2. Position solenoid in main casing.
3. Apply sealant, Part No. STC 4600 to solenoid

cover

4. Fit cover and Belleville washer.
5. Fit bolts securing interlock solenoid and tighten

to 10 Nm (7 lbf.ft).

6. Connect and secure multiplug.
7. Lower vehicle on ramp.

Solenoid - interlock - from 03 MY

$% 41.20.63

Remove

1. Remove differential lock selector cable.

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TRANSFER BOX - LT230SE,

REPAIRS, Cable - selector - differential lock.

2. Remove nut securing lever to selector housing

cross shaft and remove lever from shaft.

3. Release insert from solenoid multiplug, remove

wire terminals and remove multiplug body.

4. Remove sealant from solenoid and gear

selector housing.

5. Remove circlip securing solenoid to gear

selector housing and remove solenoid from
housing.

Refit

1. Fit solenoid to gear selector housing, feeding

harness through hole in housing.

2. Fit circlip to secure solenoid and apply STC

50551 to seal solenoid to housing.

3. Fit wires to multiplug body and fit insert into

multiplug.

4. Fit lever to cross shaft and tighten nut to 25 Nm

(18 lbf.ft).

5. Fit differential lock selector cable.

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TRANSFER BOX - LT230SE,

REPAIRS, Cable - selector - differential lock.

TRANSFER BOX - LT230SE

REPAIRS

41-41

Sensor - neutral

$% 41.20.64

Remove

1. Raise vehicle on ramp.

2. Disconnect multiplug from neutral sensor.
3. Remove sensor and discard sealing washer.

Refit

1. Clean sensor threads.
2. Fit new washer and apply sealant, Part No.

STC 50552 to threads of sensor.

3. Fit and tighten sensor to 25 Nm (18 lbf.ft).
4. Lower vehicle on ramp.

Sensor - oil temperature - If fitted

$% 41.20.80

Remove

1. Lower vehicle.

2. Disconnect 2 Lucar connectors from oil

temperature sensor.

3. Remove oil temperature sensor and discard

sealing washer.

Refit

1. Clean sensor and mating face on transfer box.
2. Fit new sealing washer, position oil

temperature sensor and tighten to 25 Nm (18
lbf.ft).

3. Connect Lucar connectors to oil temperature

sensor.

4. Lower vehicle.

TRANSFER BOX - LT230SE

41-42

REPAIRS

Switch - high low - warning

$% 41.30.05

Remove

1. Raise vehicle on a ramp.

2. Release switch multiplug from bracket on

transfer box and disconnect from harness.

3. Remove switch from transfer box and discard

sealing washer.

Refit

1. Ensure sealing washer, switch thread and

mating face on transfer box is clean.

2. Fit sealing washer to switch, fit and tighten

switch to transfer box to 25 Nm (18 lbf.ft) .

3. Connect multiplug to harness and fit multiplug

to bracket on transfer box.

4. Lower vehicle.

Switch(es) - differential lock warning
From 03 MY

$% 41.30.06

Remove

1. Remove front propeller shaft.

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PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

2. Release and disconnect both differential lock

warning switch multiplugs.

3. Remove differential lock front warning switch,

remove and discard sealing washer.

4. Remove differential lock rear warning switch,

remove and discard sealing washer.

Refit

1. Clean switches and mating face on transfer

gearbox.

2. Apply sealant, STC 50552 to switch threads.
3. Use new sealing washers, fit and tighten

differential lock warning switches to 26 Nm (19
lbf.ft)

4. Connect and secure both switch multiplugs.
5. Fit front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.