Discovery 2. Manual — part 561

TRANSFER BOX - LT230SE

OVERHAUL

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Inspect

1. Check mating surfaces of cross shaft and

housing bore for wear.

2. Check core plug in housing for signs of leakage

or corrosion ; apply Loctite 326 to replacement
plug.

3. Measuring across widest portion of finger,

check high/low selector finger for wear.

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Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in).

4. Check bearing track recesses in housing for

damage, rectify or replace housing as
necessary.

5. If fitted: Carry out inspection of differential

lock components using following procedures.

6. Check differential lock selector shaft and

housing bore for wear.

7. Measuring across the widest portion, check

differential lock finger for wear.

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Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in).

8. Check differential lock selector finger groove in

selector shaft.

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Groove width = 16.0 to 16.1 mm (0.63 to
0.64 in).

9. Check detent grooves in differential lock

selector shaft for wear.

10. Check differential lock detent ball for flat spots

and check detent spring for distortion.

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OVERHAUL

11. Check differential lock selector fork for cracks

and wear.

12. Check selector fork finger width.

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Finger width = 7.92 to 7.97 mm (0.311 to
0.313 in).

13. Check differential lock selector fork clips for

wear and damage. Check spring for distortion
and free length.

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Spring free length = 84.58 mm (3.33 in).

14. Check dog clutch internal teeth and grooves

and teeth on output shaft for wear and
damage. Check selector fork groove width.

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Groove width = 8.05 to 8.20 mm (0.32 to
0.33 in).

15. Carry out the following inspection procedures

for all transfer boxes.

16. Check threads and splines of output shaft for

damage and wear. Check dog clutch teeth on
shaft for wear and damage.

17. 03 MY onwards: Compress high/low selector

fork spring and remove retaining clips from
each end of spring, remove high/low selector
shaft.

18. Check detent grooves in high/low selector shaft

for wear. Do not remove fork from shaft
unless either component is being renewed.
If fork is removed from shaft, coat the
threads of the set screw with Loctite 290
prior to assembling.

Note: High/low selector shaft fitted to pre 03 MY
illustrated.

TRANSFER BOX - LT230SE

OVERHAUL

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19. Check width of high/low selector groove.

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Groove width = 16.0 to 16.1 mm (0.63 to
0.64 in).

20. Check high/low selector fork for cracks and

wear. Check selector fork finger width.

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Finger width = 7.37 to 7.47 mm (0.290 to
0.294 in).

21. 03 MY onwards: Check high/low selector fork

clips for wear and damage. Check spring for
distortion, check free length of spring:

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Spring free length = 75 mm (2.95 in)

Note: High/low selector shaft, fork and spring
fitted to 03 MY transfer boxes may be fitted to
pre 03 MY boxes as an assembly.

22. Check differential sun and planet gears for

wear, cracks and chipping of teeth.

23. Check cross shafts and recesses in both halves

of differential carrier for damage and
wear.Ensure planet gears are retained with
their respective shafts.

24. Check retaining ring for distortion.
25. Check differential splines for wear and

damage.

26. Check high/low hub for cracks, chipping and

uneven wear. Check width of selector fork
groove.

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Groove width = 7.5 to 7.6 mm (0.295 to 0.30
in).

27. Check splines and teeth on high/low selector

sleeve for uneven wear, cracks, damage and
chipping.

28. Check teeth of high and low range gears for

cracks, chipping and uneven wear.

29. Check high range gear bush for wear and

damage.

Reassembly

1. Lubricate all components with recommended

oil and lightly oil the differential bolt threads.

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OVERHAUL

2. Secure rear half of differential carrier in a soft

jawed vice.

3. Fit each planet gear to its respective cross

shaft, fit new dished thrust washer to each
gear.

4. Fit cross shafts, planet gears and dished thrust

washers in rear half of carrier.Ensure that
cross shafts are fitted correctly. Do not fit
the sun gear into the rear half carrier at this
stage.

5. Fit retaining ring.
6. Fit a 1.05 mm (0.04 in) thrust washer to sun

gear from front half of carrier. Position gear in
front half of carrier.

7. Ensuring that assembly marks are aligned, fit

both halves of carrier together.

8. Fit the differential carrier bolts and, working in a

diagonal sequence, tighten the bolts to 60 Nm,
(44 lbf.ft).

9. Insert the front output shaft into the front half of

the carrier and check that the gears rotate
freely.

10. Fit output flange on to the splines of the output

shaft, but do not fit flange nut at this stage.

11. Fit transmission brake drum to output flange

and secure the drum using 2 nuts.

12. Secure a length of cord around the drum and

attach one end of the cord to a spring balance.

13. Pull on the spring balance and note the load at

which the brake drum starts to turn. Used
gears should rotate smoothly, while new
gears will have a 'notchy' feel as they rotate.

14. Compare the figure obtained with the following.

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Used gears = 0.45 kg (1.0 lb)

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New gears = 1.72 kg (3.8 lb)

15. If the load to turn figure is below the specified

limits, proceed as follows.

16. Remove the front output shaft and brake drum.
17. Remove the 8 bolts securing the two halves of

the differential carrier

18. Separate the differential carrier and remove the

sun gear and thrust washer from the front half.

19. Select a thicker thrust washer from the range

available. 5 different thrust washers are
available, rising in increments of 0.10 mm
(0.004 in) from 1.05 mm to 1.45 mm (0.04 to
0.06 in).

20. Repeat steps 7 to 19 as necessary until the

load to turn figure is as specified

21. When specified load to turn is obtained,

proceed as follows.

22. Remove the front output shaft and brake drum.
23. Remove the 8 bolts securing the two halves of

the differential carrier

24. Separate the differential carrier and remove the

sun gear and thrust washer from the front
half.Retain the selected thrust washer with
its sun gear.