Discovery 2. Manual — part 558

TRANSFER BOX - LT230SE

REPAIRS

41-35

3. Fit new seal using tool LRT-41-012.
4. Position drive flange, fit new felt and steel

washers.

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

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

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

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

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

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

10. Top-up transfer box oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

Gasket - rear output shaft housing

$% 41.20.55

Remove

1. Drain transfer gearbox oil.

+

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 3254 to mating

flange on output shaft housing.

3. Fit output shaft housing to main casing.
4. Apply Loctite 290 to 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

41-36

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 3254 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.

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 Hylosil PL 32 to

sensor threads.

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

TRANSFER BOX - LT230SE

REPAIRS

41-37

Sensor - oil temperature

$% 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 42 Nm (31
lbf.ft).

3. Connect Lucar connectors to oil temperature

sensor.

4. Lower vehicle.

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 26 Nm (19 lbf.ft) .

3. Connect multiplug to harness and fit multiplug

to bracket on transfer box.

4. Lower vehicle.

TRANSFER BOX - LT230SE

41-38

REPAIRS