landrover Workshop Repair Guides

Land Rover Workshop Service and Repair Manuals

Differential assembly|Page 697 > < Differential assembly|Page 695
Page 586
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TRANSFER BOX - LT230SE

OVERHAUL

41-61

41. Position selected shim in front output  housing 

and using tool LRT-54-003, fit new  differential 
front bearing track. 

42. Fit bearing spacer to output shaft with  chamfer 

on spacer towards threaded end. 

43.  If fitted: Fit dog clutch with flange on clutch  

facing towards splined end. 

44. Using a copper mallet, drive output  shaft into 

bearing. 

Note: Carry out the following operations for 
transfer boxes fitted with differential lock.

45. Compress differential lock selector  spring and 

fit selector fork. 

46. Position selector fork to groove in  dog clutch. 
47. Fit selector shaft and locate in housing  recess, 

rotate shaft until the two flats  for retaining clips 
are at right angles to  the cover plate mating 
face. 

48. Compress selector spring and fit  retaining clips 

at each end of spring. 

CAUTION: Ensure ends of spring are fully 
seated in recess of clips.

49. Apply sealant, Part No. STC 4600 to front  

output shaft housing. 

50. Position housing ensuring that output  shaft and 

dog clutch splines - if fitted  are correctly  
engaged. 

51. Clean output shaft housing bolt threads.
52. Apply sealant, Part No. STC 50552 to threads 

of bolts. 

53. Fit  output shaft housing bolts and tighten in a  

diagonal sequence to 45 Nm (33 lbf.ft).  

54. Apply sealant, Part No. STC 4600 to mating 

face of high/low selector housing.

55. Position high/low selector housing to front 

output housing ensuring that high/low selector 
finger is located in groove in selector shaft.

56. 03 Model Year onwards: Position multiplug 

and selector cable brackets to high/low selector 
housing

57. Apply sealant, Part No. STC 50552 to threads 

of selector housing bolts.

58. Up to 03 Model Year: Fit bolts  and tighten to 

25 Nm (18 lbf.ft).

59. Fit differential lock detent ball and spring. 
60. Apply sealant, Part No. STC 50552 to threads 

of differential lock detent  plug. 

61. 03 Model Year onwards - differential lock 

fitted: Fit and tighten detent plug, then  loosen 
2 complete turns. 

62. 03 Model Year onwards - differential lock 

fitted: Apply sealant, Part No. STC 50552 to 
threads of differential lock detent plug.

63. 03 Model Year onwards - differential lock 

fitted: Fit detent ball and spring.

Differential assembly|Page 697 > < Differential assembly|Page 695