2002 LAND ROVER DISCOVERY oil

TRANSFER BOX - LT230SE
41-12 DESCRIPTION AND OPERATION
Rear output housing components
1Rear output shaft
2Rear output housing
3Bolt - rear output housing
4Spacer
5Output shaft bearing
6Circlip
7Oil seal
8Mud shield
9Rear output flange
10Felt washer
11Steel washer
12Self-locking nut

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-17
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. 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.
High/Low range and differential lock selector lever assembly – Vehicles from 03 model year
1Selector lever
2High/Low range cable
3Differential lock cable
4Interlock solenoid

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 3254 to bottom
plate sealing face.
4.Apply Loctite 290 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
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.9.Remove handbrake drum retaining screw and
remove drum.
10.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
11.Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and release outer cable from abutment bracket.

TRANSFER BOX - LT230SE
REPAIRS 41-25
12. If fitted: Disconnect 2 Lucars from differential
lock switch and disconnect multiplug from
reverse light switch.
13.Remove cable tie and multi plug from bracket
on transfer box.
14.Release transfer box breather pipe from
bulkhead clip.
15.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
16.Position gearbox support jack and secure
support plate to jack using 4 bolts. 17.Remove 3 bolts securing transfer box to
gearbox.
18.Fit 3 guide studs LRT-41-009 through
transfer box bolt holes to support it during
removal.
19.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.
20.Position a jack to support gearbox and engine.
21.Remove 4 bolts and nut, remove gearbox RH
mounting.
22.With assistance, remove transfer box from
gearbox.
23.Remove input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.

TRANSFER BOX - LT230SE
41-26 REPAIRS
Refit
1.Fit new input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
2.Clean transfer box to gearbox mating faces.
3.Raise transfer box on jack and align to guide
studs LRT-41-009.
4.Clean transfer box to gearbox bolt threads.
5.Apply Loctite 290 to bolt and stud threads.
6.Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted, apply Loctite 290 to stud threads and
tighten to 45 Nm (33 lbf.ft).
7.Remove guide studs, fit and lightly tighten
remaining 3 bolts.
8.Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft).
9.Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10.Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11.Remove 4 bolts securing support plate to
gearbox jack.
12.Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
13.Clean bottom plate bolt threads.
14.Apply Loctite 290 to threads of 4 bottom plate
bolts.
15.Fit 4 bolts securing bottom plate to transfer box
and tighten to 25 Nm (18 lbf.ft).
16.Position breather pipe and secure to bulkhead
clip.
17.Connect multiplug to reverse light switch.
18. If fitted - Connect Lucars to differential lock
switch.
19.Fit multiplug and cable tie to transfer gearbox
bracket. 20.Position high/low ratio selector cable and
secure with clevis pin.
21.Clean handbrake and mating face.
22.Position handbrake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
23.Clean handbrake drum.
24.Fit handbrake drum and tighten retaining
screw.
25.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
26.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
27.Clean exhaust silencer and mating face.
28.Position silencer, fit new gasket , connect
mounting rubbers and tighten nuts to 40 Nm
(30 lbf.ft).
29.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.

TRANSFER BOX - LT230SE
REPAIRS 41-27
Transfer box - V8
$% 41.20.25.99
Remove
1.Remove front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
2.Drain transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
3.Remove 8 bolts securing rear cross member
and remove cross member.
4.Remove 3 nuts securing intermediate silencer
to tail pipe.
5.Release silencer from mounting rubbers,
remove silencer and discard gasket.
6.Remove front propeller shaft.

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

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.8.Remove handbrake drum retaining screw and
remove handbrake drum.
9.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
10.Remove clevis pin and 'C' washer securing
high/low ratio selector cable to selector lever
and release cable from abutment bracket.

TRANSFER BOX - LT230SE
41-28 REPAIRS
11.Remove 2 cable ties securing cable to fuel
pipes.
12.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
13.Remove banjo bolt securing breather pipe and
discard washers.
14. If fitted - Disconnect 2 Lucars from differential
lock switch.
15.Release and disconnect transfer box neutral
switch multiplug. 16.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
17.Position gearbox support jack and secure
support plate to jack using 4 bolts.
18.Remove 3 bolts securing transfer box to
gearbox.
19.Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
20.Remove 2 bolts and nut securing transfer box
to gearbox case. If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
21.Position a jack to support gearbox and engine.