Page 541 of 1529

TRANSFER BOX - LT230SE
41-16 DESCRIPTION AND OPERATION
Differential lock warning lamp switch - if fitted - Vehicles up to 03 model year
A differential lock warning lamp switch connected to the SLABS ECU and operated by movement of the selector fork
and shaft is screwed into the top of the output housing. The switch connects to earth when the differential lock is
engaged.
Differential lock warning lamp switches - Vehicles from 03 model year
Vehicles from 03 model year are fitted with two differential lock warning lamp switches.
Both switches are of a new design and are fitted into the top of the front output housing. The switches are connected
to the SLABS ECU and are operated by movement of the selector shaft.
Both switches have an aluminium washer which seals the switch to the casing and also sets the switch position,
removing the requirement for a setting procedure.
Both switches are connected in parallel to earth when the differential lock is engaged. This earth is sensed by the
SLABS ECU which illuminates the differential lock warning lamp in the instrument pack.
Differential lock warning lamp - Vehicles up to 03 model year – if fitted
The differential lock warning lamp is located in the instrument pack and provides a warning to the driver when the
ignition is switched on that the differential lock is engaged. The warning lamp illuminates in a Red colour.
With the lock engaged, the traction control and electronic brake distribution warning lamps will also be illuminated.
Disengagement of the differential lock should be carried out with the ignition switched off. The warning lamps must
be extinguished when the ignition is switched on again.
Differential lock warning lamp – vehicles from 03 model year
The differential lock warning lamp is amber coloured and is located in the instrument pack.
When the lock is engaged, the warning lamp is illuminated and the instrument pack sounder emits three audible
chimes. When the lock is disengaged, the warning lamp is extinguished and the instrument pack sounder emits three
audible chimes.
Rear output housing
The rear output housing carries the output shaft and flange. A cable operated transmission brake is attached to the
housing, the brake drum being attached to the output flange.
The rear output shaft is supported in the housing by a single bearing and is splined into the differential rear sun gear.
Lubrication
Lubrication is by splash, oil filler/level and drain plugs being located in the main casing.
Internal pressures caused by thermal expansion and contraction are avoided by the use of a plastic breather pipe
venting the interior of the box to atmosphere. The pipe is attached to the top of the high/low selector housing by a
banjo bolt and is then routed in a continuously rising path into the engine compartment where the open end is secured
by a clip attached to the engine cylinder block.
Oil temperature warning lamp switch
An oil temperature switch is fitted to V8 engine models up to 03 Model Year. In the event of the transfer box oil
approaching maximum recommended working temperature of 145°C (293°F), the switch will close and a warning
lamp in the instrument pack will be illuminated.
Page 666 of 1529
REAR AXLE
DESCRIPTION AND OPERATION 51-1
REAR AXLE DESCRIPTION AND OPERAT ION
Rear axle component layout
1Drive shaft
2'O' ring
3Hub bearing
4Stake nut
5Hub flange
6Breather tube
7Bolt
8Bolt
9Oil seal10Pinion flange
11Centralising peg
12Bolt
13Washer
14Differential unit
15Drain plug
16Axle casing
17Oil level plug
18'O' ring
Page 667 of 1529

REAR AXLE
51-2 DESCRIPTION AND OPERATION
Description
General
The rear axle consists of an axle casing with a differential unit attached to the right of the vehicle centre line. A wheel
hub is installed in each end of the axle casing and connected to the differential unit by a drive shaft.
Axle casing
The axle casing is of welded construction, with brackets on the casing exterior for attachment to the rear suspension.
A differential cover on the rear of the axle casing contains an oil level plug for checking and replenishment of the
differential unit lubricating oil. A magnetic drain plug is installed on the underside of the axle casing.
The interior of the axle casing is ventilated through a breather tube inserted in a red plastic sleeve in the top of the
casing. The open end of the breather tube is located between the chassis and the left rear wheelarch.
Differential unit
The differential unit is of the spiral bevel type, lubricated by splash oil. The unit consists of a differential carrier
attached to a pinion housing. In the pinion housing, the pinion is splined to a pinion flange which is secured with a bolt
and washer. An oil seal prevents leakage past the pinion flange.
Centralising peg
The centralising peg is a press fit in the centre of the pinion flange and provides a positive location for the rear
propellor shaft to ensure it is centralised with the flange.
Page 673 of 1529
REAR AXLE
51-8 REPAIRS
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate oil seal lip with clean differential oil.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-51-010, fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).
5.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.
6.Position propeller shaft and align reference
marks.
7.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (55 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Check differential oil level.
+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0047A
LRT-51-003
Page 680 of 1529
FRONT AXLE
DESCRIPTION AND OPERATION 54-1
FRONT AXLE DESCRIPTION AND OPERAT ION
Front axle component layout
1Stake nut
2Hub flange
3Hub bearing
4Steering knuckle
5Drive shaft
6Oil seal
7Bolt
8Bolt
9Washer10Drive flange
11Oil seal
12Differential unit
13Drain plug
14Axle casing
15Breather tube
16Oil level plug
17'O' ring
Page 681 of 1529

FRONT AXLE
54-2 DESCRIPTION AND OPERATION
Description
General
The front axle consists of an axle casing with a differential unit attached to the right of the vehicle centre line. A wheel
hub is installed in a steering knuckle at each end of the axle casing and connected to the differential unit by a drive
shaft.
Axle casing
The axle casing is of welded construction, with brackets on the casing exterior for attachment to the front suspension.
Yokes at each end of the casing incorporate upper and lower ball joints for attachment of the steering knuckles.
A differential cover on the front of the axle casing contains an oil level plug for checking and replenishment of the
differential lubricating oil. A magnetic drain plug is installed on the underside of the casing. An oil seal is installed in
each end of the axle casing to prevent leakage past the drive shafts.
The interior of the axle casing is ventilated through a breather tube inserted in a red plastic sleeve in the top of the
casing. The open end of the breather tube is located in the left rear corner of the engine compartment.
Differential unit
The differential unit is of the spiral bevel type, lubricated by splash oil. The unit consists of a differential carrier
attached to a pinion housing. In the pinion housing, the pinion is splined to a drive flange which is secured with a bolt
and washer. An oil seal prevents leakage past the drive flange.
Steering knuckle
The steering knuckles are mounted on upper and lower ball joints in the yokes at the end of the axle casing. A tension
collet, in the lower mounting point of each steering knuckle, accommodates manufacturing tolerances to enable the
correct tightening of both ball joints. Lugs are incorporated on the steering knuckles for attachment of the steering
system drag link and track rod.
Page 687 of 1529
FRONT AXLE
54-8 REPAIRS
6.Using a suitable lever, remove pinion oil seal.
Take care to avoid damage to oil seal
recess.Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate pinion oil seal lip with clean
differential oil.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using LRT-51-010 , fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using LRT- 51-003, restrain pinion flange and
tighten pinion flange bolt to 100 Nm (74 lbf.ft).
5.Position propeller shaft and align reference
marks. Fit nuts and bolts and tighten to 47 Nm
(35 lbf.ft).
6.Remove stand(s) and lower vehicle.
7.Check differential oil level.
+ MAINTENANCE, PROCEDURES,
Front and rear axle.
Page 689 of 1529

FRONT AXLE
54-10 REPAIRS
9.Remove oil seal from axle casing.Refit
1.Clean drive shaft oil seal recess, oil seal
running surface, wheel hub and swivel hub
mating faces.
2.Lubricate oil seal lip and running surface with
clean differential oil.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-54-012 and tool LRT-99-003,
fit new drive shaft oil seal to axle casing.
4.Apply anti-seize compound to wheel hub and
steering knuckle mating faces.
5.Ensure ABS harness is located in cut out in
steering knuckle.
6.Fit drive shaft and wheel hub to axle casing and
align wheel hub with steering knuckle. Fit wheel
hub bolts and tighten to 100 Nm (74 lbf.ft).
7.Connect ABS sensor multiplug and secure
harness to harness bracket and brake hose.
8.Fit front brake disc.
+ BRAKES, REPAIRS, Brake disc -
front.
9.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
10.Remove stand(s) and lower vehicle.
11.Check differential oil level.
+ MAINTENANCE, PROCEDURES,
Front and rear axle.