Discovery 2. Manual — part 560
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.
TRANSFER BOX - LT230SE
41-46
OVERHAUL
29. Make suitable alignment marks between high/
low selector sleeve and hub, remove selector
sleeve.
30. Using a suitable press and thrust button LRT-
41-001 remove high/low hub and low range
gear.
31. Position tool LRT-41-002 around front
differential bearing and tool LRT-41-001 thrust
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.
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