1999 LAND ROVER DISCOVERY differential

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 41-43
OVERHAUL
Intermediate gear assembly
$% 41.20.10
Disassembly
1.Remove and discard 10 bolts securing bottom
cover, remove cover.
2.Remove 7 bolts securing differential lock
selector side cover.
3.Remove side cover. 4.Release staking from intermediate shaft nut,
remove and discard nut.
5.Remove bolt securing intermediate shaft
retaining plate, remove plate.
6.Remove intermediate shaft and discard 2 'O'
rings.

TRANSFER BOX - LT230SE
41-46 OVERHAUL
14.Lubricate and fit 'O' rings to main casing and
intermediate shaft.
15.With assistance, position intermediate gear
assembly and fit intermediate shaft.
16.Rotate shaft until retaining plate can be located
on flat on shaft.
17.Apply sealant, Part No. STC 50552 to threads
of retaining plate bolt, tighten bolt to 25 Nm (18
lbf.ft).
18.Fit new intermediate shaft nut and tighten to 88
Nm (65 lbf.ft).Do not stake nut at this stage.
19.Select neutral.
20.Screw a suitable bolt into tapped hole of tool
LRT-41-005.
21.Insert tool LRT-41-005 in end of mainshaft.
22.Using a suitable torque meter on tool LRT-41-
005, check torque to turn of gear train. Torque
to turn = 2.2 Nm (19 lbf.ft). If torque to turn
figure is incorrect, repeat intermediate gear
bearing pre-load setting and re-check.
23.On completion, remove tool LRT-41-005 and
stake flange of nut into recess on intermediate
shaft.
24.Clean transfer box bottom and side covers.
25.Apply sealant, Part No. STC 4600 to bottom
and side covers.
26.Clean bottom and side cover bolt threads.
27.Apply sealant, Part No. STC 50552 to bolt
threads.
28.Position side cover and tighten bolts to 25 Nm
(18 lbf.ft).
29.Position bottom cover and tighten bolts to 25
Nm (18 lbf.ft).
Differential assembly
$% 41.20.13
Remove
1.Remove intermediate gear cluster.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Intermediate gear assembly.
2.Remove 6 bolts securing high/low cross shaft
housing, multiplug bracket and cable bracket to
front output shaft housing; remove brackets
and housing.

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
41-48 OVERHAUL
15.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut, steel and felt
washers; remove output shaft drive flange.
16.Using a copper mallet, drive output shaft from
housing, recover bearing spacer.
17. If fitted: Noting its fitted position, remove dog
clutch from output shaft. 18.Remove and discard oil seal from housing.
19.Remove and discard circlip retaining output
shaft bearing.
20.Support housing and drift out output shaft
bearing.
21.Remove and discard differential bearing track
and collect selective shim.

TRANSFER BOX - LT230SE
OVERHAUL 41-49
22.Remove plug securing high/low selector shaft
detent spring and ball, remove spring and ball.
23.Withdraw differential assembly together with
high/low selector shaft and fork.
24.Remove selector fork and shaft from
differential.
Note: Selector fork fitted to 03 MY onwards
illustrated.
25.Note position of shoulder bolt, remove 6 bolts
and remove rear output shaft housing.
26.Remove rear bearing track from main casing.
27.Secure differential in a soft jawed vice.
28.Release staking from bearing retaining nut.
29.Using tool LRT-41-007 remove and discard
bearing retaining nut.

TRANSFER BOX - LT230SE
41-50 OVERHAUL
30.Position tool LRT-99-002 to vice.
31.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.
32.Remove high range gear and bush.
33.Make suitable alignment marks between high/
low selector sleeve and hub, remove selector
sleeve.

TRANSFER BOX - LT230SE
OVERHAUL 41-51
34.Using a suitable press and thrust button LRT-
41-001 remove high/low hub and low range
gear.
35.Position tool LRT-41-002 around front
differential bearing and tool LRT-41-001 t h r u s t
button to differential shaft and press off
bearing. Disassembly
1.Secure rear half of differential carrier in a soft
jawed vice.
2.Make suitable alignment marks between front
and rear halves of differential carrier.
3.Remove 8 bolts securing front half of carrier to
rear and separate both halves of carrier.
4.Suitably identify front sun gear to front half of
carrier, then remove sun gear.
5.Remove and discard thrust washer.
6.Suitably identify each planet gear to its shaft
and fitted position of each cross shaft to rear
half of carrier
7.Remove retaining ring.
8.Remove planet gears and cross shafts, remove
and discard dished thrust washers.
9.Suitably identify rear sun gear to rear half of
carrier, then remove sun gear.
10.Remove and discard thrust washer.