1999 LAND ROVER DISCOVERY Workshop Manual

TRANSFER BOX - LT230SE
41-44 OVERHAUL
7.Remove intermediate gear assembly and
collect bearings and selective spacer.
8.Secure gear assembly in a soft jawed vice and
using a suitable drift, remove and discard
bearing tracks.
9. Up to 03 Model Year:Remove and discard
circlips.Reassembly
1. Up to 03 Model Year:Clean gears, bearings,
circlips, shaft and mating faces of front output
housing, side and bottom covers.
Note: Intermediate gear cluster and bearing
assemblies fitted to 03 Model Year boxes may
be fitted as replacements to pre 03 Model Year
boxes.
2. 03 Model Year onwards:Clean gears,
bearings and shaft.
3. Up to 03 Model Year: Fit new circlips and
using tools LRT-99-003 and LRT-41-006 fit
bearing tracks to intermediate gear, ensuring
that the bearing tracks are fully seated against
the circlips.

TRANSFER BOX - LT230SE
OVERHAUL 41-45
4. 03 Model Year onwards: Using tools LRT-99-
003 and LRT-41-006, fit bearing tracks to
intermediate gears ensuring that tracks are fully
seated against shoulders in gears.
5.Using a micrometer, measure the width of each
bearing inner track. 6.Record each reading as measurement 'A' and
'B', both measurements should fall within the
range of 21.95 to 22.00 mm (0.864 to 0.866 in).
7.Fit inner bearing track 'A' onto tool LRT-41-017
and position intermediate gear cluster onto
bearing 'A'.
8.Fit inner bearing track 'B' to intermediate gear,
apply finger pressure to bearing inner track
and rotate intermediate gear 5 to 10 turns to
settle in bearing rollers.
9.Attach a DTI to base of tool LRT-41-017 , zero
gauge on top of tool post and take 2
measurements at 180° of the step height
between the top of the tool post and the
bearing inner track. Take an average of the two
readings and record this as measurement 'C'.
Measurement 'C' should be in the range of 0.15
to 0.64 mm (0.006 to 0.025 in).
10.Using the formula 103.554 mm (4.0769 in) -'A'-
'B'-'C', calculate the length of bearing spacer
required. From the result of the calculation
round DOWN to the nearest length of spacer
available to give a correct bearing pre-load of
0.005 mm (0.002 in). 40 spacers are
available ranging in length from 58.325 mm
(2.296 in) to 59.300 mm (2.335 in) rising in
increments of 0.025 mm (0.001 in).
11.Remove intermediate gear assembly from tool
LRT-41-017.
12.Lubricate and fit bearings and selected spacer
to intermediate gear.
13.Position tool LRT-41-004 through bearings
and spacer.

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.