Discovery 2. Manual — part 561
TRANSFER BOX - LT230SE
OVERHAUL
41-47
Inspect
1. Check mating surfaces of cross shaft and
housing bore for wear.
2. Check core plug in housing for signs of leakage
or corrosion ; apply Loctite 326 to replacement
plug.
3. Measuring across widest portion of finger,
check high/low selector finger for wear.
l
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in).
4. Check bearing track recesses in housing for
damage, rectify or replace housing as
necessary.
5. If fitted: Carry out inspection of differential
lock components using following procedures.
6. Check differential lock selector shaft and
housing bore for wear.
7. Measuring across the widest portion, check
differential lock finger for wear.
l
Finger width = 15.90 to 15.95 mm (0.625 to
0.627 in).
8. Check differential lock selector finger groove in
selector shaft.
l
Groove width = 16.0 to 16.1 mm (0.63 to
0.64 in).
9. Check detent grooves in differential lock
selector shaft for wear.
10. Check differential lock detent ball for flat spots
and check detent spring for distortion.
TRANSFER BOX - LT230SE
41-48
OVERHAUL
11. Check differential lock selector fork for cracks
and wear.
12. Check selector fork finger width.
l
Finger width = 7.92 to 7.97 mm (0.311 to
0.313 in).
13. Check differential lock selector fork clips for
wear and damage. Check spring for distortion
and free length.
l
Spring free length = 84.58 mm (3.33 in).
14. Check dog clutch internal teeth and grooves
and teeth on output shaft for wear and
damage. Check selector fork groove width.
l
Groove width = 8.05 to 8.20 mm (0.32 to
0.33 in).
15. Carry out the following inspection procedures
for all transfer boxes.
16. Check threads and splines of output shaft for
damage and wear. Check dog clutch teeth on
shaft for wear and damage.
17. 03 MY onwards: Compress high/low selector
fork spring and remove retaining clips from
each end of spring, remove high/low selector
shaft.
18. Check detent grooves in high/low selector shaft
for wear. Do not remove fork from shaft
unless either component is being renewed.
If fork is removed from shaft, coat the
threads of the set screw with Loctite 290
prior to assembling.
Note: High/low selector shaft fitted to pre 03 MY
illustrated.
TRANSFER BOX - LT230SE
OVERHAUL
41-49
19. Check width of high/low selector groove.
l
Groove 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.
l
Finger 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:
l
Spring 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.
l
Groove 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
41-50
OVERHAUL
2. Secure rear half of differential carrier in a soft
jawed vice.
3. Fit each planet gear to its respective cross
shaft, fit new dished thrust washer to each
gear.
4. Fit cross shafts, planet gears and dished thrust
washers in rear half of carrier.Ensure that
cross shafts are fitted correctly. Do not fit
the sun gear into the rear half carrier at this
stage.
5. Fit retaining ring.
6. Fit a 1.05 mm (0.04 in) thrust washer to sun
gear from front half of carrier. Position gear in
front half of carrier.
7. Ensuring that assembly marks are aligned, fit
both halves of carrier together.
8. Fit the differential carrier bolts and, working in a
diagonal sequence, tighten the bolts to 60 Nm,
(44 lbf.ft).
9. Insert the front output shaft into the front half of
the carrier and check that the gears rotate
freely.
10. Fit output flange on to the splines of the output
shaft, but do not fit flange nut at this stage.
11. Fit transmission brake drum to output flange
and secure the drum using 2 nuts.
12. Secure a length of cord around the drum and
attach one end of the cord to a spring balance.
13. Pull on the spring balance and note the load at
which the brake drum starts to turn. Used
gears should rotate smoothly, while new
gears will have a 'notchy' feel as they rotate.
14. Compare the figure obtained with the following.
l
Used gears = 0.45 kg (1.0 lb)
l
New gears = 1.72 kg (3.8 lb)
15. If the load to turn figure is below the specified
limits, proceed as follows.
16. Remove the front output shaft and brake drum.
17. Remove the 8 bolts securing the two halves of
the differential carrier
18. Separate the differential carrier and remove the
sun gear and thrust washer from the front half.
19. Select a thicker thrust washer from the range
available. 5 different thrust washers are
available, rising in increments of 0.10 mm
(0.004 in) from 1.05 mm to 1.45 mm (0.04 to
0.06 in).
20. Repeat steps 7 to 19 as necessary until the
load to turn figure is as specified
21. When specified load to turn is obtained,
proceed as follows.
22. Remove the front output shaft and brake drum.
23. Remove the 8 bolts securing the two halves of
the differential carrier
24. Separate the differential carrier and remove the
sun gear and thrust washer from the front
half.Retain the selected thrust washer with
its sun gear.
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