1999 LAND ROVER DISCOVERY oil

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.
lUsed gears = 0.45 kg (1.0 lb)
lNew 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
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
41-60 OVERHAUL
31.Position depth block tool LRT-41-014/2 and
cross bar tool LRT-41-014/1 to front output
housing.
32.Position DTI to tool LRT-41-014/1 cross bar
and zero DTI on depth block.
33.Position DTI to cross bar and record reading
obtained.
34. Using the formula: 3.05 mm (0.120 in)+B-
A=D where: B=Height difference recorded
between depth block and cross bar.
A=Average of readings to differential front
bearing outer track. D=Thickness of shim
required to give differential bearing pre-load of
0.05 mm (0.002 in).
35.From the resultant figure obtained, select
appropriate thickness shim from the range
available.
36.Shims are available from 2.00 to 3.25 mm
(0.08 to 0.13 in) thickness, rising in increments
of 0.05 mm (0.002 in). 37.Heat the front output housing to 100°C (210°F)
and fit new output shaft bearing using tool
LRT-41-011.
38.Allow housing to air cool.
39.Fit new bearing retaining circlip ensuring that
circlip is fully seated.
40.Using tool LRT-41-012, fit new output shaft oil
seal. Check that oil seal is just contacting
circlip.
CAUTION: Oil seal must be fitted dry.

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.

TRANSFER BOX - LT230SE
41-68 OVERHAUL
Input gear/bearing
$% 41.20.60
Disassembly
1.Make alignment marks between cover plate/
bearing housing and main casing.
2.Remove 5 bolts and stud nut securing cover/
bearing housing to main casing. Remove cover
and bearing housing.
3.Remove input gear assembly. 4.Remove and discard oil seal from main casing.
5.Drift out bearing track from main casing.

TRANSFER BOX - LT230SE
41-70 OVERHAUL
7.Position dial gauge with stylus contacting input
gear, push input gear rearwards and zero
gauge.
8.Push input gear forwards and note gauge
reading.
9.Calculate thickness of shim required using the
formula - A+B+C=D where:
lA= Thickness of installed shim - 3.15 mm
(0.12 in)
lB= Recorded end-float.
lC= Required pre-load - 0.05 mm (0.002 in).
lD= Thickness of shim required.
10.If an alternative shim is required to establish
correct pre-load, fit an alternative shim. Shims
are available from 3.15 to 4.00 mm (0.12 to
0.16 in) thickness, in increments of 0.05 mm
(0.002 in).
11.Remove 2 bolts, remove bearing housing and
input gear.
12.Lubricate input gear and bearings with
recommended oil.
13.Position input gear into main casing.
14.Apply sealant, Part No. STC 4600to bearing
housing and cover.
15.Apply sealant, Part No. STC 50552 to threads
of cover bolts and stud nut.
16.Position bearing housing/cover, align reference
marks and tighten bolts and stud nut by
diagonal selection to 45 Nm (33 lbf.ft).
17.Using tool LRT-37-014 fit new input shaft oil
seal.
CAUTION: Oil seal must be fitted dry.
Low gear - differential
$% 41.20.62
Disassembly
1.Remove differential.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Dog clutch - differential lock.
2.Secure differential in a soft jawed vice.
3.Release staking from bearing retaining nut.
4.Using tool LRT-41-007 remove and discard
bearing retaining nut.
5.Position tool LRT-99-002. to a vice.
6.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.

TRANSFER BOX - LT230SE
OVERHAUL 41-71
7.Remove high range gear and bush.
8.Make suitable alignment marks between high/
low selector sleeve and hub, remove selector
sleeve. 9.Using a suitable press and thrust button LRT-
41-001remove high/low hub and low range
gear.
Reassembly
1.Clean differential components.
2.Lubricate components with gearbox oil.
3.Fit differential in soft jawed vice, and fit low
range gear with dog teeth facing uppermost.
4.Fit high/low hub ensuring that machined
groove on hub teeth faces towards low range
gear.
5.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
6.Fit bush to high range gear ensuring collar is
uppermost.
7.Fit high range gear and bush onto shaft.

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-1
AUTOMATIC GE ARBOX - ZF4HP22 - 24 DESCRIPTION AND OPERAT ION
Automatic gearbox component layout
1Selector lever assembly
2Gearbox
3Electronic automatic transmission ECU
4Selector position switch5Oil cooler
6Fluid lines
7Breather tube
8Selector cable