Discovery 2. Manual — part 565

TRANSFER BOX - LT230SE

OVERHAUL

41-63

7. Remove high range gear and bush.
8. Make suitable alignment marks between high/

low selector sleeve and hub, remove selector
sleeve.

9. Using a suitable press and thrust button LRT-

41-001remove high/low hub and low range
gear.

Reassembly

1. Clean differential components.
2. Lubricate components with gearbox oil.
3. Fit differential in soft jawed vice, and fit low

range gear with dog teeth facing uppermost.

4. Fit high/low hub ensuring that machined

groove on hub teeth faces towards low range
gear.

5. Fit high/low selector sleeve ensuring that

alignment marks on hub and sleeve are
together.

6. Fit bush to high range gear ensuring collar is

uppermost.

7. Fit high range gear and bush onto shaft.

TRANSFER BOX - LT230SE

41-64

OVERHAUL

8. Fit rear bearing using tool LRT-41-008.

9. Fit new bearing retaining nut and using tool

LRT-41-007, tighten to 72 Nm (53 lbf.ft).

10. Using a suitable drift, stake collar of nut into

differential shaft recess.

11. Fit high/low selector shaft detent ball and

spring.

12. Apply Loctite 290 sealant to threads of detent

plug.

13. Fit and tighten plug, then loosen 2 complete

turns.

14. Fit differential.

+

TRANSFER BOX - LT230SE,

OVERHAUL, Differential assembly.

AUTOMATIC GEARBOX - ZF4HP22 - 24

DESCRIPTION AND OPERATION

44-1

AUTOMATIC GEARBOX - ZF4HP22 - 24

DESCRIPTION AND OPERATION

Automatic gearbox component layout

1 Selector lever assembly
2 Gearbox
3 Electronic automatic transmission ECU
4 Selector position switch
5 Oil cooler
6 Fluid lines
7 Breather tube
8 Selector cable

AUTOMATIC GEARBOX - ZF4HP22 - 24

44-2

DESCRIPTION AND OPERATION

Control schematic