1999 LAND ROVER DISCOVERY Workshop Manual

TRANSFER BOX - LT230SE
ADJUSTMENTS 41-21
ADJUST ME NTS
Cable - selector - differential lock - adjust
$% 41.20.11
Check
1.Check operation of differential lock selection
and adjust cable if required.
Adjust
1.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
2.Loosen locknuts securing outer cable to
abutment bracket.
3.Move differential lock selector lever to non
differential lock position.
4.Move differential lever on transfer gearbox fully
forward to rotate selector shaft anti-clockwise
into the non differential lock detent position.
CAUTION: Should the lever move past the
detent, allow it to move back into the non
differential lock detent position before
adjusting the cable.
5.Without moving levers, simultaneously tighten
differential lock outer cable locknuts either side
of the abutment bracket to 30 Nm (22 lbf.ft).
6.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
Cable - high/low selector
$% 41.20.46
Adjust
1.Raise vehicle on ramp.
2.Using a suitable crows foot spanner, loosen
lock nuts securing outer cable to abutment
bracket.
3.Select high range by moving lever on transfer
gearbox fully forward.
4.Insert tool LRT-41-016 through hole in selector
lever and housing. This ensures selector
lever is in the high range position.
5.Check that tool LRT-41-016 is a sliding fit in
selector lever and housing.
6.Simultaneously tighten high/low selector cable
lock nuts either side of abutment bracket to 30
Nm (22 lbf.ft) .
7.Remove tool LRT-41-016 from gear selector
lever and housing.
8.Lower vehicle on ramp.

TRANSFER BOX - LT230SE
REPAIRS 41-23
REPAIRS
Bottom cover - transfer box
$% 41.20.06
Remove
1.Raise vehicle on ramp.
2.Drain transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
3.Remove 8 bolts securing cross member to
chassis and remove cross member.
4.Remove 10 bolts securing bottom cover to
transfer box and remove cover. Refit
1.Clean bottom plate and mating face on transfer
box.
2.Clean bolt threads.
3.Apply sealant, Part No. STC 4600 to bottom
plate sealing face.
4.Apply sealant, Part No. STC 50552 to bolt
threads.
5.Position bottom plate and tighten bolts to 25
Nm (18 lbf.ft).
6.Position cross member to chassis and tighten
bolts to 26 Nm (19 lbf.ft).
7.Fill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
8.Lower vehicle on ramp.

TRANSFER BOX - LT230SE
41-24 REPAIRS
Cable - selector - differential lock
$% 41.20.12
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
2.Remove 4 bolts securing transfer gearbox high/
low selector lever to transmission tunnel.
3.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
4. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
5. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low select cable.
6.Release and remove clevis pin and 'C' clip
securing transfer gearbox high/low selector
cable to transfer gearbox high/low selector
lever. Position the cable aside.7.Release and remove clevis pin securing
differential lock selector cable to transfer
gearbox.
8.Loosen locknuts securing differential lock
selector cable to differential lock selector cable
abutment bracket.
9.Release and remove differential lock selector
cable from differential lock selector cable
abutment bracket.
10.Remove transfer gearbox high/low selector
lever assembly from transmission tunnel.
11.Release and remove clevis pin and 'C' clip
securing differential lock selector cable to
differential lock selector lever. Remove the
differential lock selector cable.

TRANSFER BOX - LT230SE
REPAIRS 41-25
Refit
1.Fit differential lock selector cable to differential
lock selector lever and secure with clevis pin
and 'C' clip.
2.Position transfer gearbox high/low selector
lever assembly to transmission tunnel.
3.Position differential lock selector cable to
differential lock selector cable abutment
bracket and tighten locknuts sufficiently to
retain cable.
4.Fit differential lock selector cable to transfer
gearbox and secure with clevis pin.
5.Fit transfer gearbox high/low selector cable to
transfer gearbox high/low selector lever and
secure with clevis pin and 'C' clip.
6.Fit transfer gearbox high/low selector lever to
transmission tunnel, fit bolts and tighten to 10
Nm (7 lbf.ft).
7. Models fitted with high/low shift interlock
solenoid: Position interlock solenoid harness
to high/low shift cable, fit sleeve around cable
and harness and secure sleeve.
8. Models fitted with high/low shift interlock
solenoid: Connect solenoid multiplug to main
harness and secure multiplug to bracket.
9.Check and adjust differential lock selector
cable.

+ TRANSFER BOX - LT230SE,
ADJUSTMENTS, Cable - selector -
differential lock - adjust.
10.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
Transfer box - Diesel
$% 41.20.25.99
Remove
1.Remove front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
2.Raise vehicle on ramp.
3.Drain transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
4.Remove 3 nuts securing intermediate silencer
to tail pipe.
5.Release silencer from mounting rubbers.
6.Remove silencer and discard gasket.
7.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
8.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

TRANSFER BOX - LT230SE
41-26 REPAIRS
9.Remove handbrake drum retaining screw and
remove drum.
10.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
11. Models fitted with high/low shift interlock
solenoid: Release interlock solenoid multiplug
and disconnect multiplug from main harness.
12. Models fitted with high/low shift interlock
solenoid: Remove sleeve retaining rings and
remove sleeve from high/low selector cable.
13. If fitted: Release and remove clevis pin
securing differential lock selector cable to
transfer gearbox.14. If fitted: Loosen locknuts securing differential
lock selector cable to differential lock selector
cable abutment bracket.
15. If fitted: Release and remove differential lock
selector cable from differential lock selector
cable abutment bracket.
16.Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and release outer cable from abutment bracket.
17. Up to 03 Model Year - if fitted: Disconnect 2
Lucars from differential lock switch and
multiplugs from high/low ratio switch and
neutral sensor.
18.Disconnect multiplug from reverse light switch.

TRANSFER BOX - LT230SE
REPAIRS 41-27
19. 03 Model Year onwards - if fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
20.Remove cable tie and multi plug from bracket
on transfer box.
21.Release transfer box breather pipe from
bulkhead clip.
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.
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.