Discovery 2. Manual — part 139

TRANSFER BOX - LT230SE

OVERHAUL

41-59

20. Apply sealant, Part No. STC 50552 to bolt

threads fit housing to main case, fit bolts and
tighten by diagonal selection to 45 Nm (33
lbf.ft).

21. 03 Model Year onwards: Fit high/low selector

fork and spring to high/low selector shaft, fit
retaining clips.

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

22. Position high/low selector shaft and fork to

differential ensuring that fingers of selector fork
are located in selector sleeve.

23. Position differential assembly into main casing

ensuring that splines of rear output shaft are
engaged in differential.

24. Position new differential front bearing track

ensuring that track is seated squarely.

25. Position tool LRT-41-014/3 onto main casing.
26. Screw tool LRT-41-014/4 into tapped hole in

main casing and attach suitable DTI to pillar.

27. Position stylus of gauge to setting block LRT-

41-014/3 and zero gauge.

28. Position stylus onto front bearing outer track

and record reading.

29. Taking care not to disturb bearing, position

stylus on opposite side of bearing track and
record reading.

30. Obtain average of the 2 readings and record

figure.

TRANSFER BOX - LT230SE

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OVERHAUL

31. Position depth block tool LRT-41-014/2 and

cross bar tool LRT-41-014/1 to front output
housing.

32. Position DTI to tool LRT-41-014/1 cross bar

and zero DTI on depth block.

33. Position DTI to cross bar and record reading

obtained.

34. Using the formula: 3.05 mm (0.120 in)+B-

A=D where: B=Height difference recorded
between depth block and cross bar.
A=Average of readings to differential front
bearing outer track. D=Thickness of shim
required to give differential bearing pre-load of
0.05 mm (0.002 in).

35. From the resultant figure obtained, select

appropriate thickness shim from the range
available.

36. Shims are available from 2.00 to 3.25 mm

(0.08 to 0.13 in) thickness, rising in increments
of 0.05 mm (0.002 in).

37. Heat the front output housing to 100

°

C (210

°

F)

and fit new output shaft bearing using tool
LRT-41-011.

38. Allow housing to air cool.
39. Fit new bearing retaining circlip ensuring that

circlip is fully seated.

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

seal. Check that oil seal is just contacting
circlip.

CAUTION: Oil seal must be fitted dry.

TRANSFER BOX - LT230SE

OVERHAUL

41-61

41. Position selected shim in front output housing

and using tool LRT-54-003, fit new differential
front bearing track.

42. Fit bearing spacer to output shaft with chamfer

on spacer towards threaded end.

43. If fitted: Fit dog clutch with flange on clutch

facing towards splined end.

44. Using a copper mallet, drive output shaft into

bearing.

Note: Carry out the following operations for
transfer boxes fitted with differential lock.

45. Compress differential lock selector spring and

fit selector fork.

46. Position selector fork to groove in dog clutch.
47. Fit 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.

48. Compress selector spring and fit retaining clips

at each end of spring.

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

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

output shaft housing.

50. Position housing ensuring that output shaft and

dog clutch splines - if fitted are correctly
engaged.

51. Clean output shaft housing bolt threads.
52. Apply sealant, Part No. STC 50552 to threads

of bolts.

53. Fit output shaft housing bolts and tighten in a

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

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

face of high/low selector housing.

55. Position high/low selector housing to front

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

56. 03 Model Year onwards: Position multiplug

and selector cable brackets to high/low selector
housing

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

of selector housing bolts.

58. Up to 03 Model Year: Fit bolts and tighten to

25 Nm (18 lbf.ft).

59. Fit differential lock detent ball and spring.
60. Apply sealant, Part No. STC 50552 to threads

of differential lock detent plug.

61. 03 Model Year onwards - differential lock

fitted: Fit and tighten detent plug, then loosen
2 complete turns.

62. 03 Model Year onwards - differential lock

fitted: Apply sealant, Part No. STC 50552 to
threads of differential lock detent plug.

63. 03 Model Year onwards - differential lock

fitted: Fit detent ball and spring.

TRANSFER BOX - LT230SE

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OVERHAUL

64. 03 Model Year onwards - differential lock

fitted: Fit differential lock detent plug and
tighten until head of plug is level with face of
output shaft housing.

65. 03 Model Year onwards - differential lock

fitted: Using a straight edge, check that head
of plug is correctly positioned, screw plug in or
out as necessary.

66. 03 Model Year onwards - differential lock

fitted: Lubricate and fit new 'O' rings to
differential lock selector housing.

67. 03 Model Year onwards - differential lock

fitted: Fit selector housing, ensure selector
finger is located in shaft recess.

68. 03 Model Year onwards: Position cable

bracket to selector housing.

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

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

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

Fit nut to differential lock warning lamp switch
with counterbore positioned towards switch
head. The nut acts as a spacer to ensure
that switch setting is correct. Always
ensure that nut is fully tightened to switch
head (no gap).

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

of differential warning lamp switch.

72. Position switch into front output housing until

nut bottoms out on housing; tighten nut to 11
Nm (8 lbf.ft)

73. 03 Model Year onwards - differential lock

fitted: Fit new aluminium sealing washers to
differential lock warning lamp switches.

CAUTION: Ensure that replacement
washers are the same thickness as the
originals.

74. 03 Model Year onwards - differential lock

fitted: Apply sealant, Part No. STC 50552 to
threads of switches.

75. 03 Model Year onwards - differential lock

fitted: Fit switches and tighten to 25 Nm (18
lbf.ft).

76. Fit output flange, new felt washer, steel washer

and new retaining nut.

M41 7886