Discovery II
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.
