300Tdi Discovery
41
TRANSFER GEARBOX
2
REPAIR
Remove
1. Site vehicle on a ramp [hoist].
2. Disconnect battery negative lead.
3. Remove fan cowl from radiator.
4. Remove transfer gear lever knob and gaiter.
5. Raise vehicle on ramp [hoist].
6. Drain oil and refit plug.
7. Detach heat shield at front exhaust pipe to
manifold.
8. Disconnect electrics to Lambda sensors.
9. Remove catalytic converter assembly.
10. Remove chassis crossmember from under
gearbox.
11. Remove heat shield from speedometer cable at
transfer gearbox.
12. Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
13. Mark for reassembly then disconnect propeller
shaft to output flange, tie to one side.
14. Repeat on front propeller shaft to output flange.
15. Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
16. Place four 30mm long spacers between top of
hoist and adaptor plate, at securing points, and
secure adaptor plate to hoist.
17. Remove four central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer gearbox.
18. Adjust hoist to take weight of transfer gearbox.
19. Remove tie bar, transfer gearbox to main
gearbox.
20. Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
21. Repeat for left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket.
22. Remove right side mounting bracket to flexible
mounting rubber.
23. Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
24. Loosen park brake adjustment nut.
25. Remove park brake drum.
26. Remove park brake assembly complete from
rear output flange.
27. Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
28. Remove banjo bolt from breather pipe, retrieve
sealing washers and lay pipe aside.
29. Remove split [cotter] pin and washers securing
differential lock to connecting rod and disconnect
rod from lever.
30. Select low range transfer gearbox position.
31. Remove high/low rod lower lock nut and remove
rod from yoke.
32. Position hoist jack channel under bell housing.
33. Using wooden block support the main gearbox
and bell housing.
34. Remove upper and lower bolts securing transfer
gearbox to main gearbox.
35. Fit guide studs 18G 1425 to main gearbox and
move transfer gearbox rearwards to detach.
