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Discovery 2. Manual - part 556

TRANSFER BOX - LT230SE

REPAIRS

41-27

Transfer box - V8

$% 41.20.25.99

Remove

1. Remove front exhaust pipe.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Front pipe.

2. Drain transfer box oil.

MAINTENANCE, PROCEDURES,

Transfer box.

3. Remove 8 bolts securing rear cross member

and remove cross member.

4. Remove 3 nuts securing intermediate silencer

to tail pipe.

5. Release silencer from mounting rubbers,

remove silencer and discard gasket.

6. Remove front propeller shaft.

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

7. Remove rear propeller shaft.

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

8. Remove handbrake drum retaining screw and

remove handbrake drum.

9. Remove 4 bolts from handbrake back plate,

release back plate and tie aside.

10. Remove clevis pin and 'C' washer securing

high/low ratio selector cable to selector lever
and release cable from abutment bracket.

TRANSFER BOX - LT230SE

41-28

REPAIRS

11. Remove 2 cable ties securing cable to fuel

pipes.

12. Disconnect 2 Lucars from oil temperature

sensor and disconnect reverse lamp switch
multiplug.

13. Remove banjo bolt securing breather pipe and

discard washers.

14. If fitted - Disconnect 2 Lucars from differential

lock switch.

15. Release and disconnect transfer box neutral

switch multiplug.

16. Remove 4 bolts from transfer box bottom plate,

position support plate LRT-99-010 to transfer
box and tighten bolts.

17. Position gearbox support jack and secure

support plate to jack using 4 bolts.

18. Remove 3 bolts securing transfer box to

gearbox.

19. Fit 3 guide studs LRT-41-009 through transfer

box bolt holes to support it during removal.

20. Remove 2 bolts and nut securing transfer box

to gearbox case. If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.

21. Position a jack to support gearbox and engine.

TRANSFER BOX - LT230SE

REPAIRS

41-29

22. Remove 4 bolts and nut securing RH mounting

to body and transfer box.

23. Remove nut securing LH mounting to body.
24. Raise gearbox and remove RH mounting.
25. With assistance, remove transfer box from

gearbox.

26. Remove input shaft oil seal.

TRANSFER BOX - LT230SE,

REPAIRS, Oil seal - input shaft.

Refit

1. Fit new input shaft oil seal.

TRANSFER BOX - LT230SE,

REPAIRS, Oil seal - input shaft.

2. Clean transfer box to gearbox mating faces.
3. Raise transfer box on jack and align to guide

studs LRT-41-009.

4. Clean transfer box to gearbox bolt threads.
5. Apply Loctite 290 to bolt and stud threads.
6. Fit and lightly tighten 2 bolts and nut securing

transfer box to gearbox. If new stud is to be
fitted apply Loctite 290 to threads of stud
and tighten to 45 Nm (33 lbf.ft)

7. Remove guide studs, fit and lightly tighten 3

bolts.

8. Tighten bolts and nut by diagonal selection to

45 Nm (33 lbf.ft.

9. Position gearbox RH mounting and tighten

bolts to 85 Nm (63 lbf.ft).

10. Tighten gearbox RH mounting nut to 48 Nm

(35 lbf.ft).

11. Fit nut to LH mounting and tighten to 48 Nm (35

lbf.ft).

12. Remove 4 bolts securing support plate to

gearbox jack.

13. Remove 4 bolts securing support plate LRT-99-

010 to transfer box and remove plate.

14. Clean threads of bottom plate bolts.
15. Apply Loctite 290 to threads of bolts.
16. Fit 4 bolts securing bottom plate and tighten to

25 Nm (18 lbf.ft).

17. Using new washers position breather pipe and

tighten banjo bolt.

18. Connect multiplug to transfer box neutral switch

and secure harness.

19. If fitted - Connect Lucars to differential lock

switch.

20. Connect multiplug and Lucars to reverse lamp

switch and oil temperature sensor.

21. Position high/low ratio selector cable and

secure with 'C' washer and clevis pin.

22. Secure cable to fuel pipes with new cable ties.
23. Clean handbrake back plate and mating face.
24. Position handbrake back plate, fit bolts and

tighten to 75 Nm (55 lbf.ft).

25. Clean handbrake drum.
26. Fit handbrake drum and tighten retaining

screw.

27. Fit front propeller shaft.

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

28. Fit rear propeller shaft.

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

29. Clean exhaust silencer and tail pipe mating

faces.

30. Position silencer and secure on mountings,

using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).

31. Position rear cross member, fit bolts and

tighten to 26 Nm (19 lbf.ft).

32. Refill transfer box with oil.

MAINTENANCE, PROCEDURES,

Transfer box.

33. Fit front exhaust pipe.

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Front pipe.

TRANSFER BOX - LT230SE

41-30

REPAIRS

Gasket - rear cover plate

$% 41.20.30

Remove

1. Mark rear cover to bearing housing for

assembly purposes.

2. Note fitted position of stud nut, remove stud nut

and 5 bolts securing rear cover.

3. Carefully release rear cover from bearing

housing.

Refit

1. Clean rear cover, mating face on bearing

housing and sealant from stud/bolt threads.

2. Apply sealant Part No. STC 3254 to rear cover

mating face.

3. Align reference marks and position rear cover.
4. Apply Loctite 290 to stud/bolt threads, fit rear

cover plate stud nut and bolts and tighten to 25
Nm (18 lbf.ft).

5. Top-up transfer box oil.

MAINTENANCE, PROCEDURES,

Transfer box.

Switch - differential lock - Up to 03 MY

$% 41.20.34

Remove

1. Remove front propeller shaft.

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

2. Disconnect 2 Lucars from switch.
3. Remove switch and remove nut from switch.

Refit

1. Clean switch and gearbox face.

2. Fit nut to 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).

3. Apply Hylomar PL 32 sealant to switch thread.
4. Position switch into front output housing until

nut bottoms out on housing.

Content .. 554 555 556 557 ..