1995 LAND ROVER DISCOVERY Workshop Manual

41TRANSFER GEARBOX
2
DESCRIPTION AND OPERATION REAR OUTPUT DRIVE ASSEMBLY
1. Rear output shaft
2. Joint sealant
3. Speedometer drive housing
4. Speedometer drive pinion assembly
5. Speedometer worm drive
6. Spacer7. Ball bearing
8. Circlip
9. Oil seal
10. Oil shield
11. Rear output flange
12. Sealing washer

TRANSFER GEARBOX
3
DESCRIPTION AND OPERATION DIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY
1. Differential selector assembly
2. Front output housing
3. High-low ratio cross shaft assembly
4. High-low selector shaft and lever
5. High-low selector fork and shaft
6. High-low selector finger
7. Differential lock selector shaft
8. Differential lock selector fork
9. Differential lock spring and clips
10. Front output housing cover and housing
11. Felt washer, steel washer and flange nut
12. Front output flange
13. Mud shield
14. Oil seal
15. Bearing
16. Spacer
17. Circlip
18. Differential carrier, front half19. Differential carrier, rear half
20. Retaining ring
21. Front output shaft
22. Dog clutch, front drive lock-up
23. Selective shim
24. Bearing
25. Selective thrust washers
26. Sun and planet gears
27. Thrust washers
28. Cross shafts
29. Gear low
30. Hub and sleeve assembly
31. High output gear
32. Bush
33. Bearing
34. Bearing retaining nut
35. Differential lock switch
36. Differential lock detent ball and spring

41TRANSFER GEARBOX
4
DESCRIPTION AND OPERATION INTERMEDIATE GEAR AND POWER TAKE OFF
ASSEMBLY
1. Transfer case assembly
2. Transfer case bottom cover
3. Intermediate shaft and 'O' ring
4. Oil seal
5. Retaining plate and anchor screw
6. Intermediate shaft nut
7. Bearing
8. Transfer mainshaft gear
9. Selective shim10. Mainshaft transfer bearing housing
11. Joint sealant
12. Power take off cover
13. High low detent ball and spring
14. Intermediate gear cluster
15. Bearings
16. Collapsible spacer
17. Circlip

TRANSFER GEARBOX
5
DESCRIPTION AND OPERATION TRANSFER GEAR SELECTOR COMPONENTS
1. Gaiter retaining screw - 4 off
2. Gaiter
3. Gaiter support plate
4. Gate plate
5. Gasket
6. Clip
7. Pin
8. Circlip, retaining nylon seat
9. Gear lever ball10. Nylon seat
11. Cross shaft
12. Gear lever
13. Gear change housing
14. Non-metallic bushes
15. Countersunk screws
16. End cover
17. Selector fork
18. 'O' ring seals

TRANSFER GEARBOX
1
FAULT DIAGNOSIS LT230T TRANSFER BOX - OIL LEAKS
Verify that the leak is from the transfer box and not the
gearbox before proceeding.
1. Input seal.
2. Cover plate joints.
3. Front output seal.
4. Front and rear housing joint faces.
5. Rear output seal.
6. Power take off cover plate joint.
7. Bearing plate joint.

41TRANSFER GEARBOX
2
FAULT DIAGNOSIS PROCEDURE
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
the system the pipe must be removed,
inspected, rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
5.Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1.Drain the oil and remove the leaking output
flange.
2.Inspect the seal track on the flange for surface
damage. If damaged renew component.
3.Remove and discard the oil seal.
4.Inspect the seal locating bore and remove any
sharp edges which may damage the new oil
seal.
5.Fit new seal.
6.Fit the output flange and all the other parts.
7.Add oil to correct level into the gearbox.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
Cover plate gasket leaking.
1.Drain the oil and remove the leaking cover plate.
2.Remove all traces of joint sealant from both joint
faces.
3.Degrease all components and apply a thin film of
Hylomar sealant, to both joint faces.
4.Apply thread sealant to the bolts which come
into contact with gearbox oil.
5.Refit cover plate.
CAUTION: Care must be taken not to
overtighten the fixings.Leak between the main and transfer gearboxes.
1.Site vehicle onto a ramp [hoist].
2.Select neutral in transfer box and select 4th gear
in the main gearbox.
3.Run engine at 2000 rpm with the clutch/drive
engaged.
4.Observe joint between the main and transfer
boxes.
5.If oil leak is found establish if it is gear oil.
6.If so, the leak is originating from the transfer box.
7.Check the two inner (main/transfer) bolts are oil
tight, as these holes are tapped through into the
main transfer case.
8.Remove the transfer box to inspect the
mainshaft collar seal track condition, and the
front face of the transfer case for porosity.
See
Repair, LT230T Transfer Gearbox
9.If these areas require servicing, the transfer
gearbox input seal must also be renewed.
CAUTION: Avoid damaging the new seal
lip and ensure the seal is fitted flush with
the machined face. Also ensure the new
seal is not damaged when refitting the transfer
gearbox.
10.If red A.T.F type oil is seen leaking during the
workshop test, investigate the main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1.Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in the transfer case and
therefore should be considered when looking for
the source of the leak.

TRANSFER GEARBOX
1
REPAIR LT230T TRANSFER GEARBOX
Service repair no - 41.10.25
Remove
Adaptor plate for removing transfer gearbox
The transfer gearbox is removed from underneath the
vehicle. Using a transmission hoist with an adaptor
plate for securing the transfer gearbox to the hoist.
The adaptor can be manufactured locally to the
drawing below.
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

41TRANSFER GEARBOX
2
REPAIR Remove
1.Site vehicle on a ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl from radiator.
4.Remove transfer gear lever knob and gaiter.
5.Raise vehicle on ramp [hoist].
6.Drain oil and refit plug.
7.Detach heat shield at front exhaust pipe to
manifold.
8.Disconnect electrics to Lambda sensors.
9.Remove catalytic converter assembly.
10.Remove chassis crossmember from under
gearbox.
11.Remove heat shield from speedometer cable at
transfer gearbox.
12.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
13.Mark for reassembly then disconnect propeller
shaft to output flange, tie to one side.
14.Repeat on front propeller shaft to output flange.
15.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
16.Place four 30mm long spacers between top of
hoist and adaptor plate, at securing points, and
secure adaptor plate to hoist.17.Remove four central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer gearbox.
18.Adjust hoist to take weight of transfer gearbox.
19.Remove tie bar, transfer gearbox to main
gearbox.
20.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
21.Repeat for left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket.
22.Remove right side mounting bracket to flexible
mounting rubber.
23.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
24.Loosen park brake adjustment nut.
25.Remove park brake drum.
26.Remove park brake assembly complete from
rear output flange.
27.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
28.Remove banjo bolt from breather pipe, retrieve
sealing washers and lay pipe aside.
29.Remove split [cotter] pin and washers securing
differential lock to connecting rod and disconnect
rod from lever.
30.Select low range transfer gearbox position.
31.Remove high/low rod lower lock nut and remove
rod from yoke.
32.Position hoist jack channel under bell housing.
33.Using wooden block support the main gearbox
and bell housing.
34.Remove upper and lower bolts securing transfer
gearbox to main gearbox.
35.Fit guide studs 18G 1425 to main gearbox and
move transfer gearbox rearwards to detach.