1999 LAND ROVER DISCOVERY warning

TRANSFER BOX - LT230SE
REPAIRS 41-31
21. 03 Model Year onwards - if fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
22.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
23.Position gearbox support jack and secure
support plate to jack using 4 bolts. 24.Remove 3 bolts securing transfer box to
gearbox.
25.Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
26.Remove 2 bolts and nut securing transfer box
to gearbox case.
CAUTION: If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
27.Position a jack to support gearbox and engine.
28.Remove 4 bolts and nut securing RH mounting
to body and transfer box.
29.Remove nut securing LH mounting to body.
30.Raise gearbox and remove RH mounting.
31.With assistance, remove transfer box from
gearbox.
32.Remove input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.

TRANSFER BOX - LT230SE
41-32 REPAIRS
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 sealant, Part No. STC 50552 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 sealant, Part No. STC 50552 to
stud threads 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 sealant, Part No. STC 50552 to threads
of 4 bottom plate 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. Up to 03 Model Year - if fitted : Connect
Lucars to differential lock switch and multiplugs
to high/low ratio switch and neutral sensor.
20. 03 Model Year onwards - if fitted: Connect
differential lock warning lamp multiplugs,
secure harness.
21.Connect multiplug to reverse lamp switch.
22. If fitted: Connect Lucars to oil temperature
switch.
23.Position high/low ratio selector cable and
secure with 'C' clip and clevis pin.
24. If fitted: Position differential lock selector cable
to differential lock selector cable abutment
bracket and tighten locknuts sufficiently to
retain cable.
25. If fitted: Fit differential lock selector cable to
transfer gearbox and secure with clevis pin.
26. If fitted: Adjust differential lock selector cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.27. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness; secure sleeve.
28. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
29.Secure cable to fuel pipes with new cable ties.
30.Clean handbrake back plate and mating face.
31.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
32.Clean handbrake drum.
33.Fit handbrake drum and tighten retaining
screw.
34.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
35.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
36.Clean exhaust silencer and tail pipe mating
faces.
37.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
38.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
39.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
40.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.

TRANSFER BOX - LT230SE
41-42 REPAIRS
Switch - high low - warning
$% 41.30.05
Remove
1.Raise vehicle on a ramp.
2.Release switch multiplug from bracket on
transfer box and disconnect from harness.
3.Remove switch from transfer box and discard
sealing washer.
Refit
1.Ensure sealing washer, switch thread and
mating face on transfer box is clean.
2.Fit sealing washer to switch, fit and tighten
switch to transfer box to 25 Nm (18 lbf.ft) .
3.Connect multiplug to harness and fit multiplug
to bracket on transfer box.
4.Lower vehicle.
Switch(es) - differential lock warning
From 03 MY
$% 41.30.06
Remove
1.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
2.Release and disconnect both differential lock
warning switch multiplugs.
3.Remove differential lock front warning switch,
remove and discard sealing washer.
4.Remove differential lock rear warning switch,
remove and discard sealing washer.
Refit
1.Clean switches and mating face on transfer
gearbox.
2.Apply sealant, STC 50552 to switch threads.
3.Use new sealing washers, fit and tighten
differential lock warning switches to 26 Nm (19
lbf.ft)
4.Connect and secure both switch multiplugs.
5.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

TRANSFER BOX - LT230SE
OVERHAUL 41-47
3.Note position of longest bolt and remove 8 bolts
securing front output shaft housing to main
casing and remove housing.
Note: Carry out the following operations if
differential lock is fitted.
4. Differential lock fitted: Remove 3 bolts
securing differential lock selector housing and
remove housing.
5. Differential lock fitted: Remove and discard
'O' rings from selector housing.
6. Up to 03 Model Year: Remove Allen plug and
remove differential lock detent spring and ball.
7. Up to 03 Model Year: Remove differential lock
warning lamp switch and locknut.
8. 03 Model Year onwards - differential lock
fitted: Remove 2 differential lock warning lamp
switches and sealing washers.9. 03 Model Year onwards - differential lock
fitted: Note position of longest bolt and remove
8 bolts securing front output housing to main
casing and remove housing.
10. 03 Model Year onwards - differential lock
fitted: Remove 3 bolts securing differential lock
selector housing and bracket, remove bracket
and housing.
11. 03 Model Year onwards - differential lock
fitted: Remove and discard 'O' rings from
selector housing.
12. 03 Model Year onwards - differential lock
fitted: Remove detent plug, recover spring and
ball.
13. All transfer boxes fitted with differential
lock: Compress differential lock selector fork
spring and remove retaining clips from each
end of spring.
14. All transfer boxes fitted with differential
lock: Withdraw differential lock selector shaft
from front output housing, recover spring and
remove selector fork.

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.

TRANSFER BOX - LT230SE
41-62 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

TRANSFER BOX - LT230SE
41-64 OVERHAUL
Dog clutch - differential lock
$% 41.20.23
Disassembly
1.Remove 6 bolts securing high/low cross shaft
housing, multiplug bracket and selector cable
bracket to front output shaft housing; remove
brackets and housing.
2.Remove 7 bolts securing differential lock
selector side cover, remove side cover.3. Up to 03 Model Year: Note position of longest
bolt and remove 8 bolts securing front output
shaft housing to main casing and remove
housing.
4. Up to 03 Model Year: Remove 3 bolts securing
differential lock selector housing and remove
housing.
5. Up to 03 Model Year: Remove and discard 'O'
rings from selector housing.
6. Up to 03 Model Year: Remove differential
warning lamp switch and locknut.
7. Up to 03 Model Year: Remove Allen plug and
remove differential lock detent spring and ball.
8. 03 Model Year onwards: Remove 2
differential warning lamp switches and sealing
washers.

TRANSFER BOX - LT230SE
OVERHAUL 41-65
9. 03 Model Year onwards:Note position of
longest bolt and remove 8 bolts securing front
output shaft housing to main casing; remove
housing.
10. 03 Model Year onwards:Remove 3 bolts
securing differential lock selector housing and
bracket, remove housing.
11. 03 Model Year onwards:Remove and discard
'O' rings from selector housing.
12. 03 Model Year onwards:Remove differential
lock detent plug, recover spring and ball.
13.Compress differential lock selector fork spring
and remove retaining clips from each end of
spring.
14.Withdraw differential lock selector shaft from
front output housing, recover spring and
remove selector fork.
15.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut. 16.Remove and discard steel and felt washers.
Remove output shaft drive flange.
17.Using a copper mallet, drive output shaft from
housing.
18.Noting its fitted position, remove bearing
spacer from output shaft.
19.Noting its fitted position, remove dog clutch
from output shaft.
20.Remove and discard oil seal from housing.
Reassembly
1.Clean differential lock components. Remove all
traces of sealant from mating faces of
housings, side cover, bolt threads, detent plugs
and differential lock warning lamp switches.
2.Lubricate components with gearbox oil.
3.Using tool LRT-41-012, fit new output shaft oil
seal.
CAUTION: Oil seal must be fitted dry.