2002 LAND ROVER DISCOVERY differential

TRANSFER BOX - LT230SE
OVERHAUL 41-59
21.Clean threads of differential lock warning lamp
switch(es).
22.Up to 03 MY: Fit nut to switch head with
counterbore positioned towards switch head.
The nut acts as a spacer to ensure that
switch setting is correct. Always ensure
that nut is fully tightened to switch head (no
gap).
23.Apply Hylomar PL 32 sealant to threads of
differential warning lamp switch(es).
24.Up to 03 MY: Position switch into front output
housing until nut bottoms out on housing,
tighten nut to 11 Nm (8 lbf.ft).
25.03 MY onwards: Fit new sealing washers to
switches, fir switches to front output housing
and tighten to 25 Nm (18 lbf.ft).
26.Operate differential lock selector lever and
check that detent ball can be felt to positively
engage/disengage with grooves in shaft.
Screw plug in or out until setting is correct.27.Fit output flange, new felt and steel washers
and new retaining nut.
28.Using tool LRT-51-003 to restrain flange,
tighten output flange nut to 162 Nm (119 lbf.ft).

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.

TRANSFER BOX - LT230SE
41-64 OVERHAUL
8.Fit rear bearing using tool LRT-41-008.
9.Fit new bearing retaining nut and using tool
LRT-41-007, tighten to 72 Nm (53 lbf.ft).
10.Using a suitable drift, stake collar of nut into
differential shaft recess.
11.Fit high/low selector shaft detent ball and
spring.
12.Apply Loctite 290 sealant to threads of detent
plug.
13.Fit and tighten plug, then loosen 2 complete
turns.
14.Fit differential.

+ TRANSFER BOX - LT230SE,
OVERHAUL, Differential assembly.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-27
11.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
12.Remove front propeller shaft

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

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
14.Remove and discard 3 bolts securing torque
converter to drive plate.
15.Remove handbrake drum retaining screw and
remove brake drum. 16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
17.Remove clip securing high/low ratio selector
cable to transfer gearbox lever, remove 'C' clip
and remove outer cable from gearbox.
18.Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
19.Remove cable tie and multi plug from bracket
to transfer box.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-30 REPAIRS
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucars to differential
lock switch.
16.Position cable tie and multi plug to transfer box
bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit rear propeller shaft.

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

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
24.Fill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
25.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
26.Position intermediate silencer and secure to
mounting rubbers.
27.Clean silencer and tail pipe mating faces.
28.Position new gasket to tail pipe and tighten
nuts to 25 Nm (18 lbf.ft).
29.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
30.Fit bolt securing closing plate to gearbox
housing and tighten to 7 Nm (5.2 lbf.ft).
31.Fit upper bolts securing gearbox housing to
engine and tighten to 50 Nm (37 lbf.ft).
32.Fit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
33.Tighten remaining gearbox housing to engine
bolts to 50 Nm (37 lbf.ft).
34.Connect battery earth lead.
35.Fit battery cover and secure with fixings.
36.Check and adjust selector cable.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, ADJUSTMENTS, Cable - selector.
Gearbox - convertor and transfer
gearbox - V8
$% 44.20.04.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise vehicle on a ramp.
4.Remove 8 bolts securing centre cross member
and remove cross member.
5.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
6.Remove 3 nuts securing intermediate silencer
to tail pipe.
7.Release and remove silencer from rubber
mountings.
8.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove front propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-31
11.Remove rear propeller shaft

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
12.Remove plug from torque converter housing to
access torque converter bolts.
13.Remove and discard 4 bolts securing torque
converter to drive plate.
14.Remove hand brake drum retaining screw and
remove brake drum.
15.Remove 4 bolts from hand brake back plate,
release back plate and tie aside. 16.Remove retaining clip securing high/low ratio
selector cable to transfer gearbox lever,
remove 'C' clip and remove outer cable from
gearbox.
17.Disconnect 2 Lucars from differential lock
switch and multiplugs from high/low ratio switch
and neutral sensor.
18.Remove cable tie and multiplug from bracket
on transfer gearbox.
19.Release transfer and automatic gearbox
breather pipes from clip at rear of cylinder
block.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-33
27.Remove 'C' clip securing selector cable to
gearbox bracket.
28.Remove nut securing selector lever to inhibitor
switch and release lever.
29.Disconnect multiplug from inhibitor switch.
30.Loosen gearbox multiplug locking ring and
disconnect plug.
31.Lower gearbox sufficiently to access bell
housing bolts, take care not to trap any pipes or
cables when lowering gearbox.
32.Remove 14 bolts securing gearbox to engine.
33.With assistance remove gearbox from engine.34.Fit suitable strap to retain torque converter.
Refit
1.Clean gearbox to engine mating faces.
2.Remove torque converter retaining strap.
3.With assistance position gearbox to engine.
4.Fit gearbox bell housing bolts and tighten to 46
Nm (34 lbf.ft)..
5.Connect multiplug to gearbox and tighten
locking ring.
6.Connect inhibitor switch multiplug.
7.Position selector lever to inhibitor switch and
tighten nut to 25 Nm (18 lbf.ft).
8.Position selector cable to gearbox and secure
with 'C' clip.
9.Clean oil pipe unions and fit new 'O' rings.
10.Position and tighten pipe unions to gearbox.
11.Position and tighten oil cooler pipe clamps.
12.Position and tighten oil cooler pipe clip to
engine sump.
13.Position engine RH and LH rear mountings
and tighten bolts to 85 Nm (63 lbf.ft) and nuts to
85 Nm (63 lbf.ft).
14.Secure gearbox breather pipes to bulkhead
clip.
15.Connect multiplugs to high/low ratio switch and
neutral sensor. Connect Lucar connectors to
differential lock switch.
16.Position cable tie and multiplug to transfer
gearbox bracket.
17.Connect high/low ratio cable to transfer box
and secure with retaining clips.
18.Position hand brake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
19.Fit hand brake drum and tighten screw.
20.Remove bolts securing tool LRT-99-008A to
gearbox.
21.Rotate engine to align torque converter, fit new
bolts and tighten to 50 Nm (37 lbf.ft).
22.Fit access plug to torque converter housing.
23.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.