Discovery II
TRANSFER BOX - LT230SE
OVERHAUL
41-65
9. 03 Model Year onwards:Note position of
longest bolt and remove 8 bolts securing front
output shaft housing to main casing; remove
housing.
10. 03 Model Year onwards:Remove 3 bolts
securing differential lock selector housing and
bracket, remove housing.
11. 03 Model Year onwards:Remove and discard
'O' rings from selector housing.
12. 03 Model Year onwards:Remove differential
lock detent plug, recover spring and ball.
13. Compress differential lock selector fork spring
and remove retaining clips from each end of
spring.
14. Withdraw differential lock selector shaft from
front output housing, recover spring and
remove selector fork.
15. Position tool LRT-51-003 to output shaft drive
flange, remove and discard nut.
16. Remove and discard steel and felt washers.
Remove output shaft drive flange.
17. Using a copper mallet, drive output shaft from
housing.
18. Noting its fitted position, remove bearing
spacer from output shaft.
19. Noting its fitted position, remove dog clutch
from output shaft.
20. Remove and discard oil seal from housing.
Reassembly
1. Clean differential lock components. Remove all
traces of sealant from mating faces of
housings, side cover, bolt threads, detent plugs
and differential lock warning lamp switches.
2. Lubricate components with gearbox oil.
3. Using tool LRT-41-012, fit new output shaft oil
seal.
CAUTION: Oil seal must be fitted dry.