2002 LAND ROVER DISCOVERY oil

TRANSFER BOX - LT230SE
OVERHAUL 41-49
19.Check width of high/low selector groove.
lGroove width = 16.0 to 16.1 mm (0.63 to
0.64 in).
20.Check high/low selector fork for cracks and
wear. Check selector fork finger width.
lFinger width = 7.37 to 7.47 mm (0.290 to
0.294 in).
21.03 MY onwards: Check high/low selector fork
clips for wear and damage. Check spring for
distortion, check free length of spring:
lSpring free length = 75 mm (2.95 in)
Note: High/low selector shaft, fork and spring
fitted to 03 MY transfer boxes may be fitted to
pre 03 MY boxes as an assembly.
22.Check differential sun and planet gears for
wear, cracks and chipping of teeth.
23.Check cross shafts and recesses in both halves
of differential carrier for damage and
wear.Ensure planet gears are retained with
their respective shafts.
24.Check retaining ring for distortion.
25.Check differential splines for wear and
damage.26.Check high/low hub for cracks, chipping and
uneven wear. Check width of selector fork
groove.
lGroove width = 7.5 to 7.6 mm (0.295 to 0.30
in).
27.Check splines and teeth on high/low selector
sleeve for uneven wear, cracks, damage and
chipping.
28.Check teeth of high and low range gears for
cracks, chipping and uneven wear.
29.Check high range gear bush for wear and
damage.
Reassembly
1.Lubricate all components with recommended
oil and lightly oil the differential bolt threads.

TRANSFER BOX - LT230SE
41-52 OVERHAUL
Refit
1.Clean differential components.
2.Lubricate components with gearbox oil.
3.Position differential in soft jawed vice and fit
front bearing using tool LRT-41-008.
4.Invert differential in soft jawed vice, and fit low
range gear with dog teeth facing uppermost. 5.Fit high/low hub ensuring that machined
groove on hub teeth faces towards low range
gear.
6.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
7.Fit bush to high range gear ensuring collar is
uppermost.
8.Fit high range gear and bush onto shaft.
9.Fit new rear bearing using tool LRT-41-008.
10.Using tool LRT-41-007, fit new bearing
retaining nut and tighten to 72 Nm (53 lbf.ft).
Do not stake nut at this stage.

TRANSFER BOX - LT230SE
OVERHAUL 41-55
37.Heat the front output housing to 100°C (210°F)
and fit new output shaft bearing using tool
LRT-41-011.
38.Allow housing to air cool.
39.Fit new bearing retaining circlip ensuring that
circlip is fully seated.
40.Using tool LRT-41-012, fit new output shaft oil
seal. Check that oil seal is just contacting
circlip. 41.Position selected shim in front output housing
and using tool LRT-54-003, fit new differential
front bearing track.
42.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
43. If fitted: Fit dog clutch with flange on clutch
facing towards splined end.
44.Using a copper mallet, drive output shaft into
bearing.
Note: Carry out the following operations for
transfer boxes fitted with differential lock.
45.Compress differential lock selector spring and
fit selector fork.
46.Position selector fork to groove in dog clutch.
47.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face.

TRANSFER BOX - LT230SE
41-58 OVERHAUL
10.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut.
11.Remove and discard steel and felt washers.
Remove output shaft drive flange.
12.Using a copper mallet, drive output shaft from
housing.
13.Noting its fitted position, remove bearing
spacer from output shaft.
14.Noting its fitted position, remove dog clutch
from output shaft.
15.Remove and discard oil seal from housing. Reassembly
1.Clean differential lock components.
2.Lubricate components with gearbox oil.
3.Using tool LRT-41-012, fit new output shaft oil
seal.
4.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
5.Fit dog clutch with flange on clutch facing
towards splined end.
6.Using a copper mallet, drive output shaft into
bearing.
7.Compress differential lock selector spring and
fit selector fork.
8.Position selector fork to groove in dog clutch.
9.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face.
10.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
11.Fit detent ball and spring.
12.Apply Loctite 290 to threads of detent plug.
13.Fit and tighten detent plug, then unscrew 2
complete turns.
14.Fit new 'O' ring to differential lock selector
housing.
15.Fit selector housing, ensure selector finger is
located in shaft recess.
16.Apply Loctite 290 to threads of bolts and tighten
selector housing bolts to 25 Nm (18 lbf.ft).
17.Apply sealant, Part No. STC 3254 to front
output shaft housing.
18.Position housing ensuring that output shaft and
dog clutch splines are correctly engaged.
19.Apply Loctite 290 to threads of bolts.
20.Fit front output shaft housing bolts and tighten
in a diagonal sequence to 45 Nm (33 lbf.ft).

TRANSFER BOX - LT230SE
41-60 OVERHAUL
Input gear/bearing
$% 41.20.60
Disassembly
1.Make alignment marks between cover plate/
bearing housing and main casing.
2.Remove 5 bolts and stud nut securing cover/
bearing housing to main casing. Remove cover
and bearing housing.
3.Remove input gear assembly. 4.Remove and discard oil seal from main casing.
5.Drift out bearing track from main casing.

TRANSFER BOX - LT230SE
41-62 OVERHAUL
7.Position dial gauge with stylus contacting input
gear, push input gear rearwards and zero
gauge.
8.Push input gear forwards and note gauge
reading.
9.Calculate thickness of shim required using the
formula - A+B+C=D where:
lA= Thickness of installed shim - 3.15 mm
(0.12 in)
lB= Recorded end-float.
lC= Required pre-load - 0.05 mm (0.002 in).
lD= Thickness of shim required.
10.If an alternative shim is required to establish
correct pre-load, fit an alternative shim. Shims
are available from 3.15 to 4.00 mm (0.12 to
0.16 in) thickness, in increments of 0.05 mm
(0.002 in).
11.Remove 2 bolts, remove bearing housing and
input gear.
12.Lubricate input gear and bearings with
recommended oil.
13.Position input gear into main casing.
14.Apply sealant, Part No. STC 3254 to bearing
housing and cover.
15.Position bearing housing/cover, align reference
marks and tighten by diagonal selection to 45
Nm (33 lbf.ft).
16.Using tool LRT-37-014 fit new input shaft oil
seal.
Low gear - differential
$% 41.20.62
Disassembly
1.Remove differential.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Dog clutch - differential lock.
2.Secure differential in a soft jawed vice.
3.Release staking from bearing retaining nut.
4.Using tool LRT-41-007 remove and discard
bearing retaining nut.
5.Position tool LRT-99-002. to a vice.
6.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.

TRANSFER BOX - LT230SE
OVERHAUL 41-63
7.Remove high range gear and bush.
8.Make suitable alignment marks between high/
low selector sleeve and hub, remove selector
sleeve. 9.Using a suitable press and thrust button LRT-
41-001remove high/low hub and low range
gear.
Reassembly
1.Clean differential components.
2.Lubricate components with gearbox oil.
3.Fit differential in soft jawed vice, and fit low
range gear with dog teeth facing uppermost.
4.Fit high/low hub ensuring that machined
groove on hub teeth faces towards low range
gear.
5.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
6.Fit bush to high range gear ensuring collar is
uppermost.
7.Fit high range gear and bush onto shaft.

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-1
AUTOMATIC GE ARBOX - ZF4HP22 - 24 DESCRIPTION AND OPERAT ION
Automatic gearbox component layout
1Selector lever assembly
2Gearbox
3Electronic automatic transmission ECU
4Selector position switch
5Oil cooler
6Fluid lines
7Breather tube
8Selector cable