Discovery 2. Manual — part 559

TRANSFER BOX - LT230SE

OVERHAUL

41-39

OVERHAUL

Intermediate gear assembly

$% 41.20.10

Disassembly

1. Remove and discard 10 bolts securing bottom

cover, remove cover.

2. Remove and discard 7 bolts securing

differential lock selector side cover.

3. Remove side cover.

4. Release staking from intermediate shaft nut,

remove and discard nut.

5. Remove bolt securing intermediate shaft

retaining plate, remove plate.

6. Remove intermediate shaft and discard 2 'O'

rings.

TRANSFER BOX - LT230SE

41-40

OVERHAUL

7. Remove intermediate gear assembly and

collect bearings and selective spacer.

8. Secure gear assembly in a soft jawed vice and

using a suitable drift, remove and discard
bearing tracks.

9. Up to 03 MY: Remove and discard circlips.

Reassembly

1. Clean gears, bearings, circlips and shaft.

Note: Intermediate gear cluster and bearing
assemblies fitted to 03 MY transfer boxes may
be fitted as replacements to pre 03 MY transfer
boxes.

2. Up to 03 MY: Fit new circlips and using tools

LRT-99-003 and LRT-41-006 fit bearing tracks
to intermediate gear, ensuring that the bearing
tracks are fully seated against the circlips.

3. 03 MY onwards: Using tools LRT-99-003 and

LRT-41-006, fit bearing tracks to intermediate
gears ensuring that tracks are fully seated
against shoulders in gears.

TRANSFER BOX - LT230SE

OVERHAUL

41-41

4. Using a micrometer, measure the width of each

bearing inner track.

5. Record each reading as measurement 'A' and

'B', both measurements should fall within the
range of 21.95 to 22.00 mm (0.864 to 0.866 in).

6. Fit inner bearing track 'A' onto tool LRT-41-017

and position intermediate gear cluster onto
bearing 'A'.

7. Fit inner bearing track 'B' to intermediate gear,

apply finger pressure to bearing inner track
and rotate intermediate gear 5 to 10 turns to
settle in bearing rollers.

8. Attach a DTI to base of tool LRT-41-017 , zero

gauge on top of tool post and take 2
measurements at 180

°

of the step height

between the top of the tool post and the
bearing inner track. Take an average of the two
readings and record this as measurement 'C'.
Measurement 'C' should be in the range of 0.15
to 0.64 mm (0.006 to 0.025 in).

9. Using the formula 103.554 mm (4.0769 in) -'A'-

'B'-'C', calculate the length of bearing spacer
required. From the result of the calculation
round DOWN to the nearest length of spacer
available to give a correct bearing pre-load of
0.005 mm (0.002 in). 40 spacers are
available ranging in length from 58.325 mm
(2.296 in) to 59.300 mm (2.335 in) rising in
increments of 0.025 mm (0.001 in).

10. Remove intermediate gear assembly from tool

LRT-41-017.

11. Lubricate and fit bearings and selected spacer

to intermediate gear.

12. Position tool LRT-41-004 through bearings

and spacer.

13. Lubricate and fit 'O' rings to main casing and

intermediate shaft.

14. With assistance, position intermediate gear

assembly and fit intermediate shaft.

15. Rotate shaft until retaining plate can be located

on flat on shaft.

16. Apply Loctite 290 to threads of retaining plate

bolt, tighten bolt to 25 Nm (18 lbf.ft).

17. Fit new intermediate shaft Patchlok nut and

tighten to 88 Nm (65 lbf.ft).Do not stake nut at
this stage.

TRANSFER BOX - LT230SE

41-42

OVERHAUL

18. Select neutral.
19. Screw a suitable bolt into tapped hole of tool

LRT-41-005.

20. Insert tool LRT-41-005 in end of mainshaft.
21. Using a suitable torque meter on tool LRT-41-

005, check torque to turn of gear train. Torque
to turn = 2.2 Nm (19 lbf.ft). If torque to turn
figure is incorrect, repeat intermediate gear
bearing pre-load setting and re-check.

22. On completion, remove tool LRT-41-005 and

stake flange of nut into recess on intermediate
shaft.

23. Clean transfer box bottom and side covers.
24. Apply sealant, Part No. STC 3254 to both

covers.

25. Clean bottom and side cover bolt threads.
26. Apply Loctite 290 to bolt threads.
27. Position side cover and tighten bolts to 25 Nm

(18 lbf.ft).

28. Position bottom cover and tighten bolts to 25

Nm (18 lbf.ft).

Differential assembly

$% 41.20.13

Remove

1. Remove intermediate gear cluster.

+

TRANSFER BOX - LT230SE,

OVERHAUL, Intermediate gear assembly.

2. Remove 6 bolts securing high/low cross shaft

housing to front output shaft housing and
remove housing.

3. Note position of longest bolt and remove 8 bolts

securing front output shaft housing to main
casing and remove housing.

Note: Carry out the following operations if
differential lock is fitted.