1995 LAND ROVER DISCOVERY gearbox

R380
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Slave cylinder to bell housing 25....................................................................
Breather 15.....................................................................................................
Bell housing to cylinder block 40.....................................................................
High/low level to shaft 2.................................................................................
Transfer box to gearbox 45.............................................................................
NOTE: Torque values below apply to all screws and bolts used unless otherwise specified.
METRIC Nm
M5 6...........................................................................
M6 9...........................................................................
M8 25...........................................................................
M10 45.........................................................................
M12 90.........................................................................
M14 105.........................................................................
M16 180.........................................................................
UNC / UNF
1/4 9...........................................................................
5/16 24.........................................................................
3/8 39...........................................................................
7/16 78.........................................................................
1/2 90...........................................................................
5/8 136...........................................................................

R380
1
SERVICE TOOLS ADAPTER PLATE GEARBOX
Adapter plate for removing gearbox. This can be
manufactured locally to drawing shown.
MATERIAL AND WELDING SPECIFICATION
Steel Plate BS 1449 (Grade 4 or 14)
Tube BS 4848 (Part 2)
Arc Welding BS 5135

TRANSFER GEARBOX
1
DESCRIPTION AND OPERATION LT230T TRANSFER BOX
The LT230T transfer box is a permanent 4 wheel
drive, two speed ratio reducing gearbox incorporating
high and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
A shiftlock device is fitted in some territories, it is used
as a park facility and prevents accidental gear
disengagement when the ignition is switched off. An
audible neutral alarm is also fitted. This alerts the
driver when parking to move the gear lever to the high
or low position.

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.