Discovery I (LJ) V8-4.0L (1996)
Output Shaft: All Technical Service Bulletins
Transfer Gearbox - Backlash/Clonk
Issue 2
24/05/96
37/02/96/US
SUBJECT:
Gearbox Mainshaft Spline Wear
MODEL:
Discovery
Discovery
Defender 90
AFFECTED VEHICLES:
LP
LJ
178205 Onwards
LJ
506525 Onwards
LD
976480 Onwards
DETAIL
Some customers may complain of clonks and backlash in the transmission system. This may be due to gearbox/mainshaft spline wear. The
clonk/backlash will be most apparent in stop/go traffic under overrun conditions or when maneuvering the vehicle during parking, etc. From transfer box
numbers 28D 460996 F (Discovery) and 22D 461124 F (Defender) all factory built LT230 transfer boxes have a revised design of input gear, featuring
lengthened splines and cross drilled oil feed holes. This modification eliminates the requirement for an oil feed disc (bulletin H415) and eliminates input
gear/mainshaft spline fretting/wear. Coincident with this change, the transfer box identification number has been changed to Suffix "F".
Information only:
The new parts supercede all old parts and should be used in ALL LT230 applications during repairs.
NOTE:
Do not use in conjunction with an oil feed disc, Bulletin "H415 Mainshaft Spline Wear Prevention." If a complaint of transmission clonk/backlash is
made, it is likely mainshaft spline wear has occurred. The transfer box mainshaft input gear and gearbox mainshaft must be replaced together as a
pair.
ACTION REQUIRED
If a customer complains of transmission backlash/clonk refer to the procedure below.
PARTS INFORMATION
Mainshaft/Input Gear replacement part numbers
Manual R380
FTC5087 replaces FTC4188, ratio 1:1.214,28 teeth
(Defender and Discovery)
FTC3703 - Gearbox Mainshaft (Defender and Discovery)
ZF Automatic
FTC5087 replaces FTC4188, ratio 1:1.214, 28 teeth
(Defender and Discovery)
FTC5090 replaces FTC3981 - Coupling Shaft (Defender and Discovery)
PROCEDURE