Discovery 2. Manual — part 140

TRANSFER BOX - LT230SE

OVERHAUL

41-63

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

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

78. If fitted: Operate differential lock selector lever

and check that detent ball can be felt to
positively engage/disengage with grooves in
shaft.

79. Up to 03 Model Year - differential lock

fitted:Screw plug in or out until setting is
correct.

80. Fit high/low selector shaft detent ball and

spring.

81. Apply sealant, Part No. STC 50552 to threads

of high/low selector shaft detent plug.

82. Up to 03 Model Year - differential lock fitted:

Fit and tighten plug, then loosen 2 complete
turns.

83. 03 Model Year onwards - differential lock

fitted: Fit detent plug and tighten until head of
plug is level with face of main casing. Using a
straight edge, check that plug is correctly
positioned; screw plug in or out as necessary.

84. 03 Model Year onwards - differential lock

fitted: Operate high/low selector lever and
check that detent ball can be felt to positively
engage/disengage with grooves in shaft.

85. Up to 03 Model Year - differential lock fitted:

Screw plug in or out until setting is correct.

86. Fit intermediate gear cluster.

+

TRANSFER BOX - LT230SE,

OVERHAUL, Intermediate gear assembly.

M41 7888

TRANSFER BOX - LT230SE

41-64

OVERHAUL

Dog clutch - differential lock

$% 41.20.23

Disassembly

1. Remove 6 bolts securing high/low cross shaft

housing, multiplug bracket and selector cable
bracket to front output shaft housing; remove
brackets and housing.

2. Remove 7 bolts securing differential lock

selector side cover, remove side cover.

3. Up to 03 Model Year: Note position of longest

bolt and remove 8 bolts securing front output
shaft housing to main casing and remove
housing.

4. Up to 03 Model Year: Remove 3 bolts securing

differential lock selector housing and remove
housing.

5. Up to 03 Model Year: Remove and discard 'O'

rings from selector housing.

6. Up to 03 Model Year: Remove differential

warning lamp switch and locknut.

7. Up to 03 Model Year: Remove Allen plug and

remove differential lock detent spring and ball.

8. 03 Model Year onwards: Remove 2

differential warning lamp switches and sealing
washers.

TRANSFER BOX - LT230SE

OVERHAUL

41-65

9. 03 Model Year onwards:Note position of

longest bolt and remove 8 bolts securing front
output shaft housing to main casing; remove
housing.

10. 03 Model Year onwards:Remove 3 bolts

securing differential lock selector housing and
bracket, remove housing.

11. 03 Model Year onwards:Remove and discard

'O' rings from selector housing.

12. 03 Model Year onwards:Remove differential

lock detent plug, recover spring and ball.

13. Compress differential lock selector fork spring

and remove retaining clips from each end of
spring.

14. Withdraw differential lock selector shaft from

front output housing, recover spring and
remove selector fork.

15. Position tool LRT-51-003 to output shaft drive

flange, remove and discard nut.

16. Remove and discard steel and felt washers.

Remove output shaft drive flange.

17. Using a copper mallet, drive output shaft from

housing.

18. Noting its fitted position, remove bearing

spacer from output shaft.

19. Noting its fitted position, remove dog clutch

from output shaft.

20. Remove and discard oil seal from housing.

Reassembly

1. Clean differential lock components. Remove all

traces of sealant from mating faces of
housings, side cover, bolt threads, detent plugs
and differential lock warning lamp switches.

2. Lubricate components with gearbox oil.

3. Using tool LRT-41-012, fit new output shaft oil

seal.

CAUTION: Oil seal must be fitted dry.

TRANSFER BOX - LT230SE

41-66

OVERHAUL

4. Fit bearing spacer to output shaft with chamfer

on spacer towards threaded end.

5. Fit dog clutch with flange on clutch facing

towards splined end.

6. Using a copper mallet, drive output shaft into

bearing.

7. Compress differential lock selector spring and

fit selector fork.

8. Position selector fork to groove in dog clutch.
9. Fit differential lock selector shaft and locate in

housing recess, rotate shaft until the two flats
for retaining clips are at right angles to the
cover plate mating face.

10. Compress differential lock selector spring and

fit retaining clips at each end of spring.

CAUTION: Ensure ends of spring are fully
seated in recess in clips.

11. Apply sealant, Part No. STC 4600 to front

output shaft housing.

12. Position housing ensuring that output shaft and

dog clutch splines are correctly engaged.

13. Apply sealant, Part No. STC 50552 to threads

of bolts.

14. Fit front output shaft housing bolts and tighten

in a diagonal sequence to 45 Nm (33 lbf.ft).

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

face of high/low selector housing.

16. Position high/low selector housing to front

output housing ensuring that high/low selector
finger is located in groove in selector shaft.

17. Position multiplug and selector cable brackets

to high/low selector housing

18. Apply sealant, Part No. STC 50552 to threads

of high/low selector housing bolts.

19. Fit bolts and tighten to 25 Nm (18 lbf.ft).

20. Fit differential lock detent ball and spring.
21. Up to 03 Model Year: Apply sealant, Part No.

STC 50552 to threads of detent plug.

22. Up to 03 Model Year: Fit and tighten detent

plug, then unscrew 2 complete turns.

23. 03 Model Year onwards: Apply sealant, Part

No. STC 50552 to threads of differential lock
detent plug.

24. Fit differential lock detent ball and spring.

25. Fit detent plug and tighten until head of plug is

level with face of housing.

26. Using a suitable straight edge, check that head

of plug is correctly positioned, screw plug in or
out as necessary.

27. Lubricate and fit new 'O' rings to differential lock

selector housing.

28. Fit selector housing, ensure selector finger is

located in shaft recess.

29. Position bracket to selector housing.
30. Apply sealant, Part No. STC 50552 to threads

of selector housing bolts, fit bolts and tighten to
25 Nm (18 lbf.ft).

M41 7886