2002 LAND ROVER DISCOVERY ECU

TRANSFER BOX - LT230SE
REPAIRS 41-35
3.Fit new seal using tool LRT-41-012.
4.Position drive flange, fit new felt and steel
washers.
5.Position tool LRT-51-003 and tighten new
drive flange nut to 148 Nm (109 lbf.ft).
6.Position handbrake drum and tighten screw.
7.Tighten brake shoe adjuster bolt to 25 Nm (18
lbf.ft) then loosen one and a half turns.
8.Check that brake drum is free to rotate.
9.Fit propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
10.Top-up transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
Gasket - rear output shaft housing
$% 41.20.55
Remove
1.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
2.Remove rear output shaft seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Seal - rear output shaft.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
1.Clean output shaft housing, mating face on
main casing and sealant from bolt threads.
2.Apply sealant, Part No. STC 3254 to mating
flange on output shaft housing.
3.Fit output shaft housing to main casing.
4.Apply Loctite 290 to bolt threads.
5.Fit output shaft housing bolts and tighten by
diagonal selection to 45 Nm (33 lbf.ft).
6.Fit rear output shaft seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Seal - rear output shaft.
7.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.

TRANSFER BOX - LT230SE
41-36 REPAIRS
Solenoid - interlock - Up to 03 MY
$% 41.20.63
Remove
1.Raise vehicle on ramp.
2.Disconnect multiplug from interlock solenoid.
3.Release multiplug retainer from mounting plate
on transfer box.
4.Remove 4 bolts securing solenoid cover,
remove cover and Belleville washer.
5.Remove solenoid.
Refit
1.Clean solenoid cover and mating face.
2.Position solenoid in main casing.
3.Apply sealant, Part No. STC 3254 to solenoid
cover.
4.Fit cover and Belleville washer.
5.Fit bolts securing interlock solenoid and tighten
to 10 Nm (7 lbf.ft).
6.Connect and secure multiplug.
7.Lower vehicle on ramp.
Sensor - neutral
$% 41.20.64
Remove
1.Raise vehicle on ramp.
2.Disconnect multiplug from neutral sensor.
3.Remove sensor and discard sealing washer.
Refit
1.Clean sensor threads.
2.Fit new washer and apply Hylosil PL 32 to
sensor threads.
3.Fit and tighten sensor to 25 Nm (18 lbf.ft).
4.Lower vehicle on ramp.

TRANSFER BOX - LT230SE
OVERHAUL 41-39
OVERHAUL
Intermediate gear assembly
$% 41.20.10
Disassembly
1.Remove and discard 10 bolts securing bottom
cover, remove cover.
2.Remove and discard 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
41-40 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 MY: Remove and discard circlips.
Reassembly
1.Clean gears, bearings, circlips and shaft.
Note: Intermediate gear cluster and bearing
assemblies fitted to 03 MY transfer boxes may
be fitted as replacements to pre 03 MY transfer
boxes.2.Up to 03 MY: 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.
3.03 MY 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.

TRANSFER BOX - LT230SE
41-42 OVERHAUL
18.Select neutral.
19.Screw a suitable bolt into tapped hole of tool
LRT-41-005.
20.Insert tool LRT-41-005 in end of mainshaft.
21.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.
22.On completion, remove tool LRT-41-005 and
stake flange of nut into recess on intermediate
shaft.
23.Clean transfer box bottom and side covers.
24.Apply sealant, Part No. STC 3254 to both
covers.
25.Clean bottom and side cover bolt threads.
26.Apply Loctite 290 to bolt threads.
27.Position side cover and tighten bolts to 25 Nm
(18 lbf.ft).
28.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 to front output shaft housing and
remove housing.
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.

TRANSFER BOX - LT230SE
OVERHAUL 41-43
4.Remove 3 bolts securing differential lock
selector housing and remove housing.
5.Remove and discard 'O' ring from selector
housing.
6.Remove Allen plug and remove detent spring
and ball.
7.Remove differential lock warning lamp switch
and locknut.
Note: Locknut is only fitted to switches up to 03
MY, a modified switch and sealing washer is
fitted from 03 MY onwards.
8.03 MY onwards: Remove differential lock
warning lamp switch from end of front output
shaft housing, discard sealing washer.
9.Compress differential lock selector fork spring
and remove retaining clips from each end of
spring.
10.Withdraw differential lock selector shaft from
front output housing, recover spring and
remove selector fork.
Note: Carry out the following operations for all
transfer boxes.11.Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut, steel and felt
washers; remove output shaft drive flange.
12.Using a copper mallet, drive output shaft from
housing, recover bearing spacer.
13. If fitted: Noting its fitted position, remove dog
clutch from output shaft.

TRANSFER BOX - LT230SE
41-44 OVERHAUL
14.Remove and discard oil seal from housing.
15.Remove and discard circlip retaining output
shaft bearing.
16.Support housing and drift out output shaft
bearing. 17.Remove and discard differential bearing track
and collect selective shim.
18.Remove Allen plug securing high/low selector
shaft detent spring and ball, remove spring and
ball.
19.Withdraw differential assembly together with
high/low selector shaft and fork.
20.Remove selector fork and shaft from
differential.
Note: Selector fork fitted to 03 MY onwards
illustrated.

TRANSFER BOX - LT230SE
OVERHAUL 41-45
21.Note position of shoulder bolt, remove 6 bolts
and remove rear output shaft housing.
22.Remove rear bearing track from main casing.
23.Secure differential in a soft jawed vice.
24.Release staking from bearing retaining nut.
25.Using tool LRT-41-007 remove and discard
bearing retaining nut. 26.Position tool LRT-99-002 to vice.
27.Position tool LRT-41-001 around rear
differential bearing, position differential to tool
LRT-99-002 and press off bearing.
28.Remove high range gear and bush.