Discovery 2. Manual — part 138

TRANSFER BOX - LT230SE

OVERHAUL

41-55

Reassembly

1. Lubricate all components with recommended

oil and lightly oil the differential bolt threads.

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.

l

Used gears = 0.45 kg (1.0 lb)

l

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.

TRANSFER BOX - LT230SE

41-56

OVERHAUL

25. Remove retaining ring, then remove the planet

gears and cross shafts.

26. Fit a 1.05 mm (0.04 in) thrust washer to sun

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

27. Fit planet gears, cross shafts and dished thrust

washers to 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.

28. Fit retaining ring.
29. Ensuring that assembly marks are aligned, fit

both halves of carrier together.

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

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

31. Invert the assembly in the vice, insert the rear

output shaft into the rear half of the carrier and
check that the gears rotate freely.

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

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

33. Fit transmission brake drum to output flange

and secure the drum using 2 nuts.

34. Carry out the load to turn check, using the same

method as for the front half carrier. Record the
shim thickness when the load to turn is correct.

35. Fit the sun gear and selected thickness shim to

the front half carrier.

36. Ensuring that assembly marks are aligned, fit

both halves of carrier together.

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

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

38. With differential assembled, fit rear output shaft

and brake drum, then check overall load to turn.
This should be approximately the same as the
combined load to turn figure of both front and
rear half carriers.

l

Used gears = 0.90 kg (2.0 lb)

l

New gears = 3.44 kg (7.6 lb)

TRANSFER BOX - LT230SE

OVERHAUL

41-57

Refit

1. Clean differential components. Remove all

traces of sealant from housings and bolts,
differential lock warning lamp switches and
detent plugs.

2. Lubricate components with gearbox oil.

3. Position differential in soft jawed vice and fit

front bearing using tool LRT-41-008.

4. Invert differential in soft jawed vice, and fit low

range gear with dog teeth facing uppermost.

5. Fit high/low hub ensuring that machined

groove on hub teeth faces towards low range
gear.

6. Fit high/low selector sleeve ensuring that

alignment marks on hub and sleeve are
together.

7. Fit bush to high range gear ensuring collar is

uppermost.

8. Fit high range gear and bush onto shaft.

9. Fit new rear bearing using tool LRT-41-008.

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OVERHAUL

10. Using tool LRT-41-007, fit new bearing

retaining nut and tighten to 72 Nm (53 lbf.ft).
Do not stake nut at this stage.

CAUTION: Ensure that threads of
replacement nut are 'Patched'.

11. Using feeler gauges, determine clearance

between low range gear and high/low hub:

l

Clearance = 0.05 to 0.15 mm (0.002 to
0.006 in).

12. If clearance is not as specified, fit a new low

range gear and high/low hub and re-check.

13. Using feeler gauges, determine clearance

between high range gear and high/low hub:

l

Clearance = 0.05 to 0.15 mm (0.002 to
0.006 in).

14. If clearance is not as specified, fit new high

range gear and high/low hub and re-check.

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

differential shaft recess.

16. Using LRT-51-009, fit new rear bearing track

into main casing.

17. Using a straight edge and feeler gauges, check

that bearing track is recessed 1 mm (0.04 in)
below outer face of main casing.

18. Apply sealant, Part No. STC 4600 to rear

output shaft housing face.

19. Position housing to main casing.