Discovery II
TRANSFER BOX - LT230SE
41-46
OVERHAUL
14. Lubricate and fit 'O' rings to main casing and
intermediate shaft.
15. With assistance, position intermediate gear
assembly and fit intermediate shaft.
16. Rotate shaft until retaining plate can be located
on flat on shaft.
17. Apply sealant, Part No. STC 50552 to threads
of retaining plate bolt, tighten bolt to 25 Nm (18
lbf.ft).
18. Fit new intermediate shaft nut and tighten to 88
Nm (65 lbf.ft).Do not stake nut at this stage.
19. Select neutral.
20. Screw a suitable bolt into tapped hole of tool
LRT-41-005.
21. Insert tool LRT-41-005 in end of mainshaft.
22. 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.
23. On completion, remove tool LRT-41-005 and
stake flange of nut into recess on intermediate
shaft.
24. Clean transfer box bottom and side covers.
25. Apply sealant, Part No. STC 4600 to bottom
and side covers.
26. Clean bottom and side cover bolt threads.
27. Apply sealant, Part No. STC 50552 to bolt
threads.
28. Position side cover and tighten bolts to 25 Nm
(18 lbf.ft).
29. Position bottom cover and tighten bolts to 25
Nm (18 lbf.ft).
Differential assembly
$% 41.20.13
Remove
1. Remove intermediate gear cluster.
OVERHAUL, Intermediate gear assembly.
2. Remove 6 bolts securing high/low cross shaft
housing, multiplug bracket and cable bracket to
front output shaft housing; remove brackets
and housing.
