Overhaul - Transfer Case (lt230se) Land Rover Discovery L318

VEHICLE APPLICATIONS

LT230SE TRANSFER CASE VEHICLE APPLICATIONS

Scheme 1

GENERAL

The LT230SE transfer box is mounted at the rear of the transfer box and transmits drive via high or low reduction ratios to the front and rear axles via the propeller shafts. The high/low ratios are 1.211:1 and 3.32:1 respectively. Transfer boxes fitted to this model have the prefixes 41D and 42D to the unit serial number. Prefix 41D denotes that the unit is not fitted with interlock while 42D denotes that interlock is fitted.

Vehicles Up To 2003 Model Year

While similar to LT230Q transfer boxes fitted to other models, the LT230SE transfer box has certain engineering modifications incorporated which are as follows

1. Up-rated torque capacity.
2. Modified front and rear output and cross shaft housings.
3. Intermediate gear bearing pre-load now controlled by a selective, non-collapsible spacer.
4. Speedometer drive and driven gears not fitted for this application.
5. Modified high/low sleeve.
6. Modified front output flange and mud shield.
7. Differential lock fitted to certain vehicles, but no longer driver operated.
8. Fixed setting of differential lock warning lamp switch on vehicles fitted with differential lock.

Vehicles From 2003 Model Year

The LT230SE transfer box is as described above for vehicles up to 03 model year with the following modifications. The following items are introduced on vehicles from 03 model year

1. Ribs added to main casing to reduce operating noise.
2. Revised machining process for intermediate gears to reduce operating noise.
3. Bearing retaining nut on the differential carrier has patchlock added to the threads.
4. Interlock solenoid moved from main casing to selector lever assembly.
5. Intermediate gears modified with machined internal shoulder and bearing circlips deleted.
6. Driver operated differential lock.
7. High/Low selector shaft fitted with spring assist.
8. Existing differential lock switch replaced by 2 new switches of improved design with the additional switch installed adjacent to the existing switch location.

CONSTRUCTION

The transfer box comprises three main assemblies

1. The Main Casing
2. The Front Output Housing
3. The Rear Output Housing

Both output housings and all cover plates are sealed to the main casing by sealant; mud and water ingress being prevented by mud shields located on the output flanges.

MAIN CASING

The main casing carries the mainshaft input gear, the intermediate gears and the differential, together with the high/low range gears, selector shaft and fork. The front and rear output housings are bolted to either side of the main casing.

Transmission Neutral Sensor

A transmission neutral sensor is fitted on automatic transfer box vehicles for North America and Japan. The sensor is connected to the Body Control Unit (BCU) and is normally in the open position. The sensor provides an earth path for the BCU which then interprets the signal and activates an audible warning generated by the IDM if neutral is selected on the transfer box when the ignition is on.

Transfer Box Interlock Solenoid - Automatic transfer box Vehicles

An interlock solenoid is fitted for North America and Japan. The solenoid is located on the top of the transfer box main casing on vehicles up to 03 model year or on the selector lever assembly on vehicles from 03 model year. The solenoid is connected to the transfer box relay which, in turn, is controlled by the IDM. The purpose of the solenoid is to prevent neutral being selected on the transfer box when the ignition key is removed, thereby locking the box in either high or low ratio.

Mainshaft Input Gear

The transfer box output shaft is splined into the mainshaft input gear which is supported by taper roller bearings.

Input gear bearing pre-load is achieved by the use of a selective shim located in the bearing housing.

Intermediate Gears

The intermediate gear cluster is supported by the taper roller bearings located at each end of the cluster and runs on the intermediate shaft which, in turn, is supported at the front and rear by the main casing.

A selective spacer, positioned between the gears, pre-loads the intermediate gear bearings when the intermediate shaft nut is tightened sufficiently to achieve the correct torque-to-turn of the intermediate gears.

On vehicles from 03 model year, the circlips used to retain the bearings in the intermediate gear are deleted. The bore of the intermediate gear is machined with a shoulder at each end to locate the bearings.

Differential Assembly

The differential assembly is supported at the front and rear by taper roller bearings, the front bearing outer track is located in the front output housing and the rear bearing outer track is located in the main casing by the rear output housing. Bearing pre-load is achieved by means of a selective shim located in the front output housing.

The differential rear shaft carries the low range gear, high/low selector sleeve and hub, high range gear and bush and the differential rear bearing; these components being secured to the shaft by a special staked nut.

The differential assembly comprises front and rear half carriers with integral shafts and with sun and planet gears mounted on cross shafts within the half carriers. Dished, non-selective thrust washers control the engagement of the planet gears with the sun gears, while selective thrust washers are used to control engagement of the sun gears and torque-to-turn of the differential. The differential carrier halves are bolted together, a retaining ring providing positive location of the cross shafts.

The high/low selector shaft and fork are located at the side of the differential, movement of the shaft, fork and selector sleeve being controlled by the high/low selector finger. A spring loaded detent ball fitted in the main casing, locates in grooves in the shaft.

On vehicles from 03 model year, the selector fork is modified and fitted with a spring assister and clips to reduce the effort required to move the selector lever.

FRONT OUTPUT HOUSING

The front output housing carries the front output shaft and flange, high/low cross shaft, housing and selector and on certain vehicles, the differential lock selector shaft and fork.

The front output shaft is supported in the housing by a single bearing and is splined into the differential front sun gear.

High/Low Selector

The high/low cross shaft is located in a housing bolted to the top of the output housing and is connected to the high/low selector finger which locates in a slot in the selector shaft.

High/Low Detect Switch

A high/low detect switch is fitted in the front output housing and connects to earth when low is selected. The switch is connected to the engine ECM, the Self-Leveling Anti-Lock Brake System (SLABS) ECU and the Electronic Traction Control (ETC) ECU. The purpose of the switch is to enable selection of the hill descent feature and to modify the engine fuelling and automatic transfer box gearshift maps stored within the respective ECM and ECU.

Differential Lock - If Fitted

The differential lock selector housing is bolted to the top of the front output housing, the selector finger passes through the housing, locating in a slot in the differential lock selector shaft. The differential lock selector shaft passes through the selector fork which is located beneath a plate bolted to the side of the output housing. The selector fork engages the dog clutch sleeve with the differential rear shaft when the splines of the sleeve and differential rear shaft are aligned. A spring loaded detent ball fitted in the output housing locates in grooves in the shaft.

Functionality (Up To 2003 Model Year) Only

The function of the differential lock used in previous applications is performed on this vehicle by the Electronic Traction Control (ETC) system. However, for the purposes of 2 wheel rolling road testing , the differential lock components are retained. For all driving conditions however, the differential lock must be set in the unlocked position.

The differential lock must only be engaged for 2 wheel rolling road testing as engagement of the lock disables the traction control feature and inhibits correct operation of the electronic brake distribution and hill descent features. It will also be necessary to disconnect the propeller shaft from the transfer box output shaft driving the axle whose wheels are NOT on the rolling road. The lock may be engaged/disengaged by using a 10-mm open ended spanner on the flats (arrowed) machined on the differential lock selector shaft. (Scheme 2)

Vehicles not fitted with a differential lock may be identified by there being no cover or selector shaft (arrowed) on the front output housing.

Scheme 2

Functionality (From 2003 Model Year Only)

The differential lock must be engaged for 2 wheel rolling road testing. It will also be necessary to disconnect the propeller shaft from the transfer box output shaft driving the axle whose wheels are NOT on the rolling road. In addition, the Electronic Traction Control (ETC) system must be deactivated by either, removing a fuse (10A fuse 28 in the passenger compartment fusebox, labelled ABS) or disconnecting the ABS modulator pump. This must be done with the ignition switched off. Note that the SLABS ECU may record a system fault.

The lock can be engaged or disengaged using the selector lever.

Differential Lock Warning Lamp Switch, If Fitted (Up To 2003 Model Year)

A differential lock warning lamp switch connected to the Self-Leveling Anti-Lock Brake System (SLABS) ECU and operated by movement of the selector fork and shaft is screwed into the top of the output housing. The switch connects to earth when the differential lock is engaged.

Differential Lock Warning Lamp Switches (From 2003 Model Year)

Vehicles from 03 model year are fitted with two differential lock warning lamp switches.

Both switches are of a new design and are fitted into the top of the front output housing. The switches are connected to the Self-Leveling Anti-Lock Brake System (SLABS) ECU and are operated by movement of the selector shaft.

Both switches have an aluminum washer which seals the switch to the casing and also sets the switch position, removing the requirement for a setting procedure.

Both switches are connected in parallel to earth when the differential lock is engaged. This earth is sensed by the SLABS ECU which illuminates the differential lock warning lamp in the instrument pack.

Differential Lock Warning Lamp (Up To 2003 Model Year, If Fitted)

The differential lock warning lamp is located in the instrument pack and provides a warning to the driver when the ignition is switched on that the differential lock is engaged. The warning lamp illuminates in a Red color.

With the lock engaged, the traction control and electronic brake distribution warning lamps will also be illuminated. Disengagement of the differential lock should be carried out with the ignition switched off. The warning lamps must be extinguished when the ignition is switched on again.

Differential Lock Warning Lamp (From 2003 Model Year)

The differential lock warning lamp is Amber colored and is located in the instrument pack.

When the lock is engaged, the warning lamp is illuminated and the instrument pack sounder emits three audible chimes. When the lock is disengaged, the warning lamp is extinguished and the instrument pack sounder emits three audible chimes.

Rear Output Housing

The rear output housing carries the output shaft and flange. A cable operated transmission brake is attached to the housing, the brake drum being attached to the output flange.

The rear output shaft is supported in the housing by a single bearing and is splined into the differential rear sun gear.

Lubrication

Lubrication is by splash, oil filler/level and drain plugs being located in the main casing.

Internal pressures caused by thermal expansion and contraction are avoided by the use of a plastic breather pipe venting the interior of the box to atmosphere. The pipe is attached to the top of the high/low selector housing by a banjo bolt and is then routed in a continuously rising path into the engine compartment where the open end is secured by a clip attached to the engine cylinder block.

Oil Temperature Warning Lamp Switch

An oil temperature switch is fitted to V8 engine models up to 2003 Model Year. In the event of the transfer box oil approaching maximum recommended working temperature of 145°C (293°F), the switch will close and a warning lamp in the instrument pack will be illuminated.

On vehicles fitted with a differential lock, the high/low range selector lever as fitted on previous models also incorporates the differential lock selector on vehicles from 03 model year.

The lever can be moved forwards or backwards to select high, neutral or low range or sideways to select differential lock engaged or disengaged, on vehicles with differential lock fitted.

The selector lever assembly comprises an aluminum casting with bosses for location of the two cables, the selector lever mechanism and a housing for the interlock solenoid (if fitted). (Scheme 3) The upper face of the casting has threaded holes which allow for the attachment of the casting to the mounting plate which is attached to the transmission tunnel.

A boss at the front provides location for the differential lock cable. The cable is attached to a lever which in turn is attached to the selector lever. Movement of the selector lever is passed via the lever to the cable which moves the differential lock selector shaft.

A second boss provides for the location of the high/low range cable. The cable is attached to a plate which moves in a forward or rearward direction with the selector lever. On North American and Japanese specification models, plate movement is prevented by an interlock solenoid when the ignition key is not in the ignition.

When fitted, the interlock solenoid is located on the right hand side of the selector lever casting. The solenoid is fitted into a cast housing in the casting and retained with a circlip. Sealant is applied over the circlip to seal the solenoid in the housing to prevent the ingress of dirt and moisture. The solenoid performs the same function as on previous models, preventing the selection of neutral on the transfer box when the ignition key is not in the ignition.

A setting procedure is required for both the differential lock cable and the high/low range cable.

Scheme 3

POWER FLOW

The transfer box output shaft transmits power to the mainshaft input gear which is in constant mesh with one of the intermediate gears. The intermediate gears are in constant mesh with the high and low range output gears running on the differential rear shaft. (Scheme 4)and (Scheme 5).

Power is transmitted to the output shafts via the differential assembly by locking either the high or low range gears to the differential rear shaft. This is achieved by means of the high/low selector fork, sleeve and splined hub.

Scheme 4

Scheme 5

COMPONENT LOCATIONS

For component locations (Scheme 6)- (Scheme 14)

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

LUBRICATION SPECIFICATIONS

LUBRICATION SPECIFICATIONS

TRANSFER BOX DRAIN & REFILL

Check/Top-Up Oil Level

1. Release fixings, remove rear underbelly panel.
2. Clean area around oil filler/level plug. (Scheme 15)
3. Remove oil filler/level plug.
4. Check that oil level is to bottom of filler/level plug hole.
5. Top-up level (if required) with recommended oil to bottom of oil filler/level plug hole. See «LUBRICATION SPECIFICATIONS»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__lubrication-specifications).
6. Fit transfer box filler/level plug and tighten to 25 N.m (18 ft. lbs.).
7. Remove all traces of oil from main casing.
8. Fit rear underbelly panel (if fitted), secure fixings.

Scheme 15

Replace Oil

1. Release fixings, remove rear underbelly panel.
2. Place a suitable container beneath transfer box drain plug.
3. Clean area around oil filler/level and drain plugs.
4. Remove oil filler/level plug. (Scheme 16)
5. Remove oil drain plug. (Scheme 16)
6. Allow oil to drain.
7. Fit transfer box drain plug and tighten to 30 N.m (22 ft. lbs.).
8. Fill transfer box with recommended oil to bottom of oil filler/level plug hole. See «LUBRICATION SPECIFICATIONS»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__lubrication-specifications).
9. Fit transfer box filler/level plug and tighten to 25 N.m (18 ft. lbs.).
10. Remove all traces of oil from transfer box.
11. Fit rear underbelly panel (if fitted), secure fixings.

Scheme 16

SEALANTS

The following table lists those sealants which are used during repair/overhaul procedures covered in this manual; it is essential that the sealant specified for a particular procedure is used at all times.

SEALANTS

Removal

1. Raise vehicle on ramp.
2. Drain transfer box oil. See «TRANSFER BOX DRAIN & REFILL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__transfer-box-drain-refill) under LUBRICATION.
3. Remove 8 bolts securing crossmember to chassis and remove crossmember. (Scheme 17)
4. Remove 10 bolts securing bottom cover to transfer box and remove cover. (Scheme 18)

Scheme 17

Scheme 18

Installation

1. Clean bottom plate and mating face on transfer box.
2. Clean bolt threads.
3. Apply sealant, Part No. STC 4600 to bottom plate sealing face.
4. Apply sealant, Part No. STC 50552 to bolt threads.
5. Position bottom plate and tighten bolts to 25 N.m (18 ft. lbs.).
6. Position crossmember to chassis and tighten bolts to 26 N.m (19 ft. lbs.).
7. Fill transfer box with oil. See «TRANSFER BOX DRAIN & REFILL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__transfer-box-drain-refill) under LUBRICATION.
8. Lower vehicle on ramp.

1. Raise vehicle on a ramp.
2. Using a suitable crowfoot spanner, remove lock nut and washer securing outer cable to abutment bracket. (Scheme 19)
3. Remove clevis pin securing inner cable to transfer box lever and release cable from abutment bracket.
4. Release C clip securing outer cable to high/low lever abutment bracket.
5. Remove clevis pin securing inner cable to high/low lever.
6. Remove bolt securing outer cable clip to cross shaft housing, remove cable. (Scheme 20)

Scheme 19

Scheme 20

1. Clean change levers, abutment bracket and clevis pins.
2. Apply Mobilith SHC 100 grease to inner cable ends and clevis pins.
3. Position cable and secure to high/low lever abutment bracket with C clip.
4. Secure inner cable to high/low lever with clevis pin.
5. Position outer cable clip to cross shaft housing, tighten bolt to 15 N.m (11 ft. lbs.).
6. Adjust high/low selector cable. See «CABLE - HIGH/LOW SELECTOR»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) under ADJUSTMENTS.

1. Remove center console. See «CENTER CONSOLE WITH A/T»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) under REMOVAL & INSTALLATION.
2. Remove 4 bolts securing transfer box high/low selector lever to transmission tunnel. (Scheme 21)
3. Remove front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
4. On models fitted with high/low shift interlock solenoid, release interlock solenoid multiplug and disconnect multiplug from main harness.
5. On models fitted with high/low shift interlock solenoid, remove sleeve retaining rings and remove sleeve from high/low select cable.
6. Release and remove clevis pin and C clip securing transfer box high/low selector cable to transfer box high/low selector lever. (Scheme 22) Position the cable aside.
7. Release and remove clevis pin securing differential lock selector cable to transfer box.
8. Loosen locknuts securing differential lock selector cable to differential lock selector cable abutment bracket. (Scheme 23)
9. Release and remove differential lock selector cable from differential lock selector cable abutment bracket.
10. Remove transfer box high/low selector lever assembly from transmission tunnel.
11. Release and remove clevis pin and C clip securing differential lock selector cable to differential lock selector lever. (Scheme 24) Remove the differential lock selector cable.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

1. Fit differential lock selector cable to differential lock selector lever and secure with clevis pin and C clip.
2. Position transfer box high/low selector lever assembly to transmission tunnel.
3. Position differential lock selector cable to differential lock selector cable abutment bracket and tighten locknuts sufficiently to retain cable.
4. Fit differential lock selector cable to transfer box and secure with clevis pin.
5. Fit transfer box high/low selector cable to transfer box high/low selector lever and secure with clevis pin and C clip.
6. Fit transfer box high/low selector lever to transmission tunnel, fit bolts and tighten to 10 N.m (7 ft. lbs.).
7. On models fitted with high/low shift interlock solenoid, Position interlock solenoid harness to high/low shift cable, fit sleeve around cable and harness and secure sleeve.
8. On models fitted with high/low shift interlock solenoid, Connect solenoid multiplug to main harness and secure multiplug to bracket.
9. Check and adjust differential lock selector cable. See «CABLE - DIFFERENTIAL LOCK SELECTOR»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) under ADJUSTMENTS.
10. Fit center console. See «CENTER CONSOLE WITH A/T»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) under REMOVAL & INSTALLATION.

1. Raise vehicle on ramp.
2. Disconnect multiplug from interlock solenoid.
3. Release multiplug retainer from mounting plate on transfer box.
4. Remove 4 bolts securing solenoid cover, remove cover and Belleville washer. (Scheme 25)
5. Remove solenoid.

Scheme 25

1. Clean solenoid cover and mating face.
2. Position solenoid in main casing.
3. Apply sealant, Part No. STC 4600 to solenoid cover.
4. Fit cover and Belleville washer.
5. Fit bolts securing interlock solenoid and tighten to 10 N.m (7 ft. lbs.).
6. Connect and secure multiplug.
7. Lower vehicle on ramp.

1. Remove differential lock selector cable. See «CABLE - DIFFERENTIAL LOCK SELECTOR»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).
2. Remove nut securing lever to selector housing cross shaft and remove lever from shaft. (Scheme 26)
3. Release insert from solenoid multiplug, remove wire terminals and remove multiplug body.
4. Remove sealant from solenoid and gear selector housing.
5. Remove circlip securing solenoid to gear selector housing and remove solenoid from housing.

Scheme 26

1. Fit solenoid to gear selector housing, feeding harness through hole in housing.
2. Fit circlip to secure solenoid and apply STC 50551 to seal solenoid to housing. (Scheme 26)
3. Fit wires to multiplug body and fit insert into multiplug.
4. Fit lever to cross shaft and tighten nut to 25 N.m (18 ft. lbs.).
5. Fit differential lock selector cable.

1. Raise vehicle on ramp.
2. Disconnect multiplug from neutral sensor. (Scheme 27)
3. Remove sensor and discard sealing washer.

Scheme 27

1. Clean sensor threads.
2. Fit NEW washer and apply sealant, Part No. STC 50552 to threads of sensor.
3. Fit and tighten sensor to 25 N.m (18 ft. lbs.).
4. Lower vehicle on ramp.

1. Raise vehicle on ramp.
2. Disconnect 2 Lucar connectors from oil temperature sensor. (Scheme 28)
3. Remove oil temperature sensor and discard sealing washer.

Scheme 28

1. Clean sensor and mating face on transfer box.
2. Fit NEW sealing washer, position oil temperature sensor and tighten to 25 N.m (18 ft. lbs.).
3. Connect Lucar connectors to oil temperature sensor.
4. Lower vehicle.

1. Remove rear propeller shaft. See «DRIVE SHAFT - REAR»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
2. Disconnect 2 Lucars from switch. (Scheme 29)
3. Remove switch and remove nut from switch.

Scheme 29

1. Clean switch and transfer box face.
2. Fit nut to switch with counterbore positioned towards switch head. (Scheme 30) The nut acts as a spacer to ensure that switch setting is correct. Always ensure that nut is fully tightened to switch head, (no gap).
3. Apply sealant, Part No. STC 50552 to switch thread.
4. Position switch into front output housing until nut bottoms out on housing.
5. Tighten nut securing differential lock switch to 11 N.m (8 ft. lbs.).
6. Connect Lucars to switch.
7. Fit front propeller shaft. See «DRIVE SHAFT - REAR»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.

Scheme 30

1. Remove front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
2. Release and disconnect both differential lock warning switch multiplugs.
3. Remove differential lock front warning switch, remove and discard sealing washer. (Scheme 31)
4. Remove differential lock rear warning switch, remove and discard sealing washer.

Scheme 31

1. Clean switches and mating face on transfer box.
2. Apply sealant, STC 50552 to switch threads.
3. Use NEW sealing washers, fit and tighten differential lock warning switches to 26 N.m (19 ft. lbs.).
4. Connect and secure both switch multiplugs.
5. Fit front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.

1. Raise vehicle on a ramp.
2. Release switch multiplug from bracket on transfer box and disconnect from harness.
3. Remove switch from transfer box and discard sealing washer. (Scheme 32)

Scheme 32

1. Ensure sealing washer, switch thread and mating face on transfer box is clean.
2. Fit sealing washer to switch, fit and tighten switch to transfer box to 25 N.m (18 ft. lbs.).
3. Connect multiplug to harness and fit multiplug to bracket on transfer box.
4. Lower vehicle.

Check

Check operation of differential lock selection and adjust cable if required.

Adjustment

1. Remove front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
2. Loosen locknuts securing outer cable to abutment bracket. (Scheme 33)
3. Move differential lock selector lever to non differential lock position.
4. Move differential lever on transfer box fully forward to rotate selector shaft counterclockwise into the non differential lock detent position.
5. Without moving levers, simultaneously tighten differential lock outer cable locknuts either side of the abutment bracket to 30 N.m (22 ft. lbs.).
6. Fit front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.

Scheme 33

1. Raise vehicle on ramp.
2. Using a suitable crows foot spanner, loosen lock nuts securing outer cable to abutment bracket. (Scheme 34)
3. Select high range by moving lever on transfer box fully forward.
4. Insert tool LRT-41-016 through hole in selector lever and housing. (Scheme 34) This ensures selector lever is in the high range position.
5. Check that tool LRT-41-016 is a sliding fit in selector lever and housing.
6. Simultaneously tighten high/low selector cable lock nuts either side of abutment bracket to 30 N.m (22 ft. lbs.).
7. Remove tool LRT-41-016 from gear selector lever and housing.
8. Lower vehicle on ramp.

Scheme 34

1. Select position D, remove gear selector knob and collect spacer. (Scheme 35)
2. On models from 2003 Model Year, remove both center console cup holders.
3. Release selector panel, disconnect multiplug and remove panel.
4. Release clips securing transfer box lever gaiter to center console and remove knob and gaiter.
5. On models with base trim, remove rubber mat from center console and remove cover plate from switch pack. (Scheme 36)
6. On models with base trim, remove 4 screws securing switch pack to center console, disconnect multiplugs and remove switch pack.
7. On models with veneer trim, release veneered console cover and remove cigar lighter element. Disconnect multiplugs from switch pack and remove veneered console cover. (Scheme 37)
8. Remove 2 bolts securing forward edge of console to transmission tunnel. (Scheme 37)
9. Release handbrake gaiter from console. (Scheme 38)
10. Remove clip and clevis pin securing cable to handbrake lever.
11. Move handbrake to fully upward position.
12. Release electric seat switches from console.
13. Disconnect multiplugs from switches and remove. (Scheme 38)
14. Remove 2 bolts securing rear of console to transmission tunnel.
15. Release center console from fascia.
16. Disconnect multiplug and bulb from cigar lighter. (Scheme 39)
17. Remove console. Do not carry out further dismantling if component is removed for access only.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Fit and secure cigar lighter body to console.
2. Fit lid to console and secure with screws.
3. Fit console.
4. Connect multiplug and bulb to cigar lighter.
5. Fit center console to fascia.
6. Fit 2 bolts securing rear of console to transmission tunnel.
7. Connect multiplugs to seat switches.
8. Fit switches to console.
9. Move handbrake to lowered position.
10. Fit cable to handbrake and secure with clevis pin and clip.
11. Fit handbrake gaiter to console.
12. Fit bolts securing forward edge of console to transmission tunnel.
13. On models with veneer trim, position veneered console cover and connect multiplugs to switch pack. Fit cigar lighter element and secure veneered console cover to console.
14. On models with base trim, connect multiplugs to switch pack, fit switch pack to console and secure with screws.
15. On models with base trim, fit cover plate to switch pack, and rubber mat to console.
16. Fit transfer box gaiter and knob to lever.
17. Secure transfer box gaiter to console.
18. Connect multiplug to selector panel, fit and secure panel to center console.
19. Fit spacer and knob to gear selector lever.
20. On models from 2003 Model Year, fit both center console cup holders.

1. Open hood. Release front HO2S multiplugs from support brackets and disconnect multiplugs. (Scheme 40)
2. Raise vehicle on ramp.
3. Where fitted, release rear HO2S multiplugs from support brackets on transfer box and disconnect multiplugs. (Scheme 41)
4. Remove 8 bolts securing crossmember and remove crossmember.
5. Remove 2 nuts securing front pipe to intermediate pipe/silencer. (Scheme 42)
6. Remove 6 nuts securing front pipe to exhaust manifolds.
7. Release front pipe and collect front pipe to manifold gaskets.
8. With assistance remove front pipe.
9. Remove HO2S from front pipe.

Scheme 40

Scheme 41

Scheme 42

1. If refitting existing HO2S, apply anti-seize compound to HO2S threads.
2. Fit HO2S to front pipe and tighten to 45 N.m (33 ft. lbs.).
3. Clean front pipe and mating faces.
4. Position front pipe, with NEW front pipe to manifold gaskets, and align front pipe with intermediate pipe/silencer and exhaust manifolds.
5. Fit and tighten exhaust manifold nuts to 30 N.m (22 ft. lbs.).
6. Fit and tighten intermediate pipe/silencer nuts to 25 N.m (18 ft. lbs.).
7. Fit chassis crossmember and tighten bolts to 25 N.m (18 ft. lbs.).
8. Connect HO2S multiplugs and secure to support brackets.

1. Mark rear cover to bearing housing for assembly purposes. (Scheme 43)
2. Note fitted position of stud nut, remove stud nut and 5 bolts securing rear cover.
3. Carefully release rear cover from bearing housing.

Scheme 43

1. Clean rear cover, mating face on bearing housing and sealant from stud/bolt threads.
2. Apply sealant Part No. STC 4600 to rear cover mating face.
3. Align reference marks and position rear cover.
4. Apply sealant, Part No. STC 50552 to stud/bolt threads, fit rear cover plate stud nut and bolts and tighten to 25 N.m (18 ft. lbs.).
5. Top-up transfer box oil. See «CHECK/TOP-UP OIL LEVEL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__checktop-up-oil-level) under TRANSFER BOX DRAIN & REFILL in LUBRICATION.

1. Drain transfer box oil. See «TRANSFER BOX DRAIN & REFILL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__transfer-box-drain-refill) under LUBRICATION.
2. Remove rear output shaft seal. See «OIL SEAL - REAR OUTPUT SHAFT»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).
3. Mark output shaft housing to main casing for assembly purposes.
4. Note position of shoulder bolt, remove 6 bolts securing housing to main casing. (Scheme 44)

Scheme 44

1. Clean output shaft housing, mating face on main casing and sealant from bolt threads.
2. Apply sealant, Part No. STC 4600 to mating flange on output shaft housing.
3. Fit output shaft housing to main casing.
4. Apply sealant, Part No. STC 50552 to output shaft housing bolt threads.
5. Fit output shaft housing bolts and tighten by diagonal selection to 45 N.m (33 ft. lbs.).
6. Fit rear output shaft seal. See «OIL SEAL - REAR OUTPUT SHAFT»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) .
7. Fill transfer box with oil. See «TRANSFER BOX DRAIN & REFILL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__transfer-box-drain-refill) under LUBRICATION.

1. Position vehicle on 4 post ramp.
2. Remove front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
3. Restrain transfer box drive flange using tool LRT-51-003. Remove and discard drive flange nut. (Scheme 45) Remove and discard steel and felt washers.
4. Using tool LRT-99-500, if necessary, remove drive flange from transfer box. (Scheme 46)
5. Remove seal from transfer box. (Scheme 47)

Scheme 45

Scheme 46

Scheme 47

1. Clean seal mating faces.
2. Fit NEW seal using tool LRT-41-012. (Scheme 48)
3. Position drive flange, fit NEW felt and steel washers.
4. Position tool LRT-51-003 and tighten NEW drive flange nut to 148 N.m (109 ft. lbs.). (Scheme 49)
5. Fit propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
6. Top-up transfer box oil. See «CHECK/TOP-UP OIL LEVEL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__checktop-up-oil-level) under TRANSFER BOX DRAIN & REFILL in LUBRICATION.

Scheme 48

Scheme 49

1. Remove transfer box. See «TRANSFER CASE ASSEMBLY»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).
2. Lever input shaft oil seal from transfer box. (Scheme 50)

Scheme 50

1. Clean oil seal recess in transfer box.
2. Using tool LRT-37-014 fit input shaft seal to transfer box. (Scheme 51)
3. Fit transfer box. See «TRANSFER CASE ASSEMBLY»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).

Scheme 51

1. Remove rear propeller shaft. See «DRIVE SHAFT - REAR»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
2. Loosen brake shoe adjuster bolt. (Scheme 52)
3. Remove screw securing handbrake drum. (Scheme 53)
4. Remove handbrake drum.
5. Restrain transfer box drive flange using tool LRT-51-003. Remove and discard drive flange nut, remove and discard steel and felt washers. (Scheme 53)
6. Using tool LRT-99-500, if necessary, remove drive flange from transfer box. (Scheme 54)
7. Remove seal from transfer box. (Scheme 55)

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Clean seal mating faces.
2. Fit NEW seal using tool LRT-41-012. (Scheme 56)
3. Position drive flange, fit NEW felt and steel washers.
4. Position tool LRT-51-003 and tighten NEW drive flange nut to 148 N.m (109 ft. lbs.). (Scheme 57)
5. Position handbrake drum and tighten screw.
6. Tighten brake shoe adjuster bolt to 25 N.m (18 ft. lbs.), then loosen one and a half turns.
7. Check that brake drum is free to rotate.
8. Fit propeller shaft. See «DRIVE SHAFT - REAR»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
9. Top-up transfer box oil. See «CHECK/TOP-UP OIL LEVEL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__checktop-up-oil-level) under TRANSFER BOX DRAIN & REFILL in LUBRICATION.

Scheme 56

Scheme 57

1. On 2003 Model Year onwards, remove upper fan cowl. Remove front exhaust pipe. See «FRONT EXHAUST PIPE»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).
2. Drain transfer box oil. See «TRANSFER BOX DRAIN & REFILL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__transfer-box-drain-refill) under LUBRICATION.
3. Remove 8 bolts securing rear crossmember and remove crossmember. (Scheme 58)
4. Remove 3 nuts securing intermediate silencer to tail pipe. (Scheme 59)
5. Release silencer from mounting rubbers, remove silencer and discard gasket.
6. Remove front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
7. Remove rear propeller shaft. See «DRIVE SHAFT - REAR»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
8. Remove handbrake drum retaining screw and remove handbrake drum. (Scheme 60)
9. Remove 4 bolts from handbrake back plate, release back plate and tie aside.
10. On models fitted with high/low shift interlock solenoid, release interlock solenoid multiplug and disconnect multiplug from main harness.
11. On models fitted with high/low shift interlock solenoid, remove sleeve retaining rings and remove sleeve from high/low selector cable.
12. If fitted, release and remove clevis pin securing differential lock selector cable to transfer box.
13. If fitted, loosen locknuts securing differential lock selector cable to differential lock selector cable abutment bracket. (Scheme 61)
14. If fitted, release and remove differential lock selector cable from differential lock selector cable abutment bracket.
15. Remove clevis pin and C clip securing high/low ratio selector cable to selector lever and release cable from abutment bracket. (Scheme 62)
16. Remove 2 cable ties securing cable to fuel pipes. (Scheme 63)
17. If fitted, disconnect 2 Lucars from oil temperature sensor and disconnect reverse lamp switch multiplug. (Scheme 64)
18. Remove banjo bolt securing breather pipe and discard washers. (Scheme 65)
19. Up to 2003 Model Year, if fitted, disconnect 2 Lucars from differential lock switch and multiplugs from high/low ratio switch and neutral sensor. (Scheme 65)
20. Disconnect multiplug from reverse light switch.
21. On 2003 Model Year onwards, if fitted, release and disconnect both differential lock warning lamp switch multiplugs from main harness. (Scheme 66)
22. Remove 4 bolts from transfer box bottom plate, position support plate LRT-99-010 to transfer box and tighten bolts. (Scheme 67)
23. Position transfer box support jack and secure support plate to jack using 4 bolts.
24. Remove 3 bolts securing transfer box to transfer box.
25. Fit 3 guide studs LRT-41-009 through transfer box bolt holes to support it during removal. (Scheme 68)
26. Remove 2 bolts and nut securing transfer box to transfer box case.
27. Position a jack to support transfer box and engine.
28. Remove 4 bolts and nut securing right hand mounting to body and transfer box. (Scheme 69)
29. On vehicles up to 2002 Model Year, remove nut securing left hand mounting to body. On vehicles 2003 Model Year onwards, remove bolts and nut securing left hand mounting to body and transfer box.
30. On vehicles up to 2002 Model Year, raise transfer box and remove right hand mounting. On vehicles 2003 Model Year onwards, raise transfer box and remove right hand and left hand mountings. On vehicles 2003 Model Year onwards, release selector cable from transmission (to allow transmission to lower fully).
31. With assistance, remove transfer box from transmission. On vehicles 2003 Model Year onwards, remove locating dowels LRT-41-009 when input seal is clear of transmission output shaft.
32. Remove transfer box input shaft oil seal. See «OIL SEAL - INPUT SHAFT»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Fit NEW input shaft oil seal. See «OIL SEAL - INPUT SHAFT»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) .
2. Clean transfer box to transfer box mating faces.
3. Raise transfer box on jack and align to guide studs LRT-41-009.
4. Clean transfer box to transfer box bolt threads.
5. Apply sealant, Part No. STC 50552 to bolt and stud threads.
6. Fit and lightly tighten 2 bolts and nut securing transfer box to transmission. If NEW stud is to be fitted, apply sealant, Part No. STC 50552 to stud threads and tighten to 45 N.m (33 ft. lbs.).
7. Remove guide studs, fit and lightly tighten 3 bolts.
8. Tighten bolts and nut by diagonal selection to 45 N.m (33 ft. lbs.).
9. Position transfer box right hand mounting and tighten bolts to 85 N.m (63 ft. lbs.).
10. Tighten transfer box right hand mounting nut to 48 N.m (35 ft. lbs.).
11. Fit nut to left hand mounting and tighten to 48 N.m (35 ft. lbs.).
12. Remove 4 bolts securing support plate to transmission jack.
13. Remove 4 bolts securing support plate LRT-99-010 to transfer box and remove plate.
14. Clean threads of bottom plate bolts.
15. Apply sealant, Part No. STC 50552 to threads of 4 bottom plate bolts.
16. Fit 4 bolts securing bottom plate and tighten to 25 N.m (18 ft. lbs.).
17. Using NEW washers position breather pipe and tighten banjo bolt.
18. Connect multiplug to transfer box neutral switch and secure harness.
19. On vehicles up to 2003 Model Year, if fitted, connect Lucars to differential lock switch and multiplugs to high/low ratio switch and neutral sensor.
20. On vehicles 2003 Model Year onwards, if fitted, connect differential lock warning lamp multiplugs, secure harness.
21. Connect multiplug to reverse lamp switch.
22. If fitted, connect Lucars to oil temperature switch.
23. Position high/low ratio selector cable and secure with C clip and clevis pin.
24. If fitted, position differential lock selector cable to differential lock selector cable abutment bracket and tighten locknuts sufficiently to retain cable.
25. If fitted, fit differential lock selector cable to transfer box and secure with clevis pin.
26. If fitted, adjust differential lock selector cable. See «CABLE - DIFFERENTIAL LOCK SELECTOR»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) under ADJUSTMENTS.
27. Models fitted with high/low shift interlock solenoid, position interlock solenoid harness to high/low shift cable, fit sleeve around cable and harness; secure sleeve.
28. Models fitted with high/low shift interlock solenoid, connect solenoid multiplug to main harness and secure multiplug to bracket.
29. Secure cable to fuel pipes with NEW cable ties.
30. Clean handbrake back plate and mating face.
31. Position handbrake back plate, fit bolts and tighten to 75 N.m (55 ft. lbs.).
32. Clean handbrake drum.
33. Fit handbrake drum and tighten retaining screw.
34. Fit front propeller shaft. See «DRIVE SHAFT - FRONT»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
35. Fit rear propeller shaft. See «DRIVE SHAFT - REAR»(/land-rover/discovery/l318-2002-2004/remont/driveshaft-universal-joints/#driveshafts-universal-joints) in DRIVESHAFT & UNIVERSAL JOINTS article.
36. Clean exhaust silencer and tail pipe mating faces.
37. Position silencer and secure on mountings, using a NEW gasket align to tail pipe, fit nuts and tighten to 25 N.m (18 ft. lbs.).
38. Position rear crossmember, fit bolts and tighten to 26 N.m (19 ft. lbs.).
39. Refill transfer box with oil. See «TRANSFER BOX DRAIN & REFILL»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se__transfer-box-drain-refill) .
40. Fit front exhaust pipe. See «FRONT EXHAUST PIPE»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se) .

Disassembly

1. Remove and discard 10 bolts securing bottom cover, remove cover. (Scheme 70)
2. Remove 7 bolts securing differential lock selector side cover. (Scheme 71)
3. Remove side cover.
4. Release staking from intermediate shaft nut, remove and discard nut. (Scheme 72)
5. Remove bolt securing intermediate shaft retaining plate, remove plate.
6. Remove intermediate shaft and discard 2 "O" rings. (Scheme 73)
7. Remove intermediate gear assembly and collect bearings and selective spacer. (Scheme 74)
8. Secure gear assembly in a soft jawed vice and using a suitable drift, remove and discard bearing tracks. (Scheme 75)
9. On vehicles up to 2003 Model Year, remove and discard circlips.

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Reassembly

1. On vehicles up to 2003 Model Year, clean gears, bearings, circlips, shaft and mating faces of front output housing, side and bottom covers.
2. On vehicles 2003 Model Year onwards, clean gears, bearings and shaft.
3. On vehicles up to 2003 Model Year, fit NEW circlips and using tools LRT-99-003 and LRT-41-006 fit bearing tracks to intermediate gear, ensuring that the bearing tracks are fully seated against the circlips. (Scheme 76)
4. On vehicles 2003 Model Year onwards, using tools LRT-99-003 and LRT-41-006, fit bearing tracks to intermediate gears ensuring that tracks are fully seated against shoulders in gears. (Scheme 77)
5. Using a micrometer, measure the width of each bearing inner track. (Scheme 78)
6. Record each reading as measurement A and B. Both measurements should fall within the range of 21.95-22.00 mm (0.864-0.866").
7. Fit inner bearing track A onto tool LRT-41-017 and position intermediate gear cluster onto bearing A.
8. Fit inner bearing track B to intermediate gear, apply finger pressure to bearing inner track and rotate intermediate gear 5 to 10 turns to settle in bearing rollers.
9. Attach a Dial Test Indicator (DTI) to base of tool LRT-41-017, zero gauge on top of tool post and take 2 measurements at 180° of the step height between the top of the tool post and the bearing inner track. Take an average of the two readings and record this as measurement C. Measurement C should be in the range of 0.15-0.64 mm (0.006-0.025"). (Scheme 79)
10. Using the formula 103.554 mm (4.0769") - A - B - C, calculate the length of bearing spacer required. From the result of the calculation round DOWN to the nearest length of spacer available to give a correct bearing pre-load of 0.005 mm (0.002"). There are 40 spacers available ranging in length from 58.325-59.300 mm (2.335-2.296") rising in increments of 0.025 mm (0.001").
11. Remove intermediate gear assembly from tool LRT-41-017.
12. Lubricate and fit bearings and selected spacer to intermediate gear.
13. Position tool LRT-41-004 through bearings and spacer.
14. Lubricate and fit "O" rings to main casing and intermediate shaft.
15. With assistance, position intermediate gear assembly and fit intermediate shaft.
16. Rotate shaft until retaining plate can be located on flat on shaft.
17. Apply sealant, Part No. STC 50552 to threads of retaining plate bolt, tighten bolt to 25 N.m (18 ft. lbs.).
18. Fit NEW intermediate shaft nut and tighten to 88 N.m (65 ft. lbs.). DO NOT stake nut at this stage.
19. Select neutral.
20. Screw a suitable bolt into tapped hole of tool LRT-41-005.
21. Insert tool LRT-41-005 in end of mainshaft. (Scheme 80)
22. Using a suitable torque meter on tool LRT-41-005, check torque to turn of gear train. Torque-to-turn = 2.2 N.m (19 ft. lbs.). If torque to turn figure is incorrect, repeat intermediate gear bearing pre-load setting and re-check.
23. On completion, remove tool LRT-41-005 and stake flange of nut into recess on intermediate shaft.
24. Clean transfer box bottom and side covers.
25. Apply sealant, Part No. STC 4600 to bottom and side covers.
26. Clean bottom and side cover bolt threads.
27. Apply sealant, Part No. STC 50552 to bolt threads.
28. Position side cover and tighten bolts to 25 N.m (18 ft. lbs.).
29. Position bottom cover and tighten bolts to 25 N.m (18 ft. lbs.).

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Remove intermediate gear cluster. See «INTERMEDIATE GEAR ASSEMBLY»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).
2. Remove 6 bolts securing high/low cross shaft housing, multiplug bracket and cable bracket to front output shaft housing; remove brackets and housing. (Scheme 81)
3. Note position of longest bolt and remove 8 bolts securing front output shaft housing to main casing and remove housing. (Scheme 82) If vehicle is fitted with differential lock, go to next step. If vehicle is not fitted with differential lock, go to step 15.
4. If differential lock is fitted, remove 3 bolts securing differential lock selector housing and remove housing. (Scheme 82)
5. If differential lock is fitted, remove and discard "O" rings from selector housing. (Scheme 82)
6. On vehicles up to 2003 Model Year, remove Allen plug and remove differential lock detent spring and ball. (Scheme 82)
7. On vehicles up to 2003 Model Year, remove differential lock warning lamp switch and locknut. (Scheme 82)
8. On vehicles 2003 Model Year onwards with differential lock fitted, remove 2 differential lock warning lamp switches and sealing washers. (Scheme 83)
9. On vehicles 2003 Model Year onwards with differential lock fitted, note position of longest bolt and remove 8 bolts securing front output housing to main casing and remove housing. (Scheme 83)
10. On vehicles 2003 Model Year onwards with differential lock fitted, remove 3 bolts securing differential lock selector housing and bracket, remove bracket and housing. (Scheme 83)
11. On vehicles 2003 Model Year onwards with differential lock fitted, remove and discard "O" rings from selector housing. (Scheme 83)
12. On vehicles 2003 Model Year onwards with differential lock fitted, remove detent plug, recover spring and ball. (Scheme 83)
13. On all transfer boxes fitted with differential lock, compress differential lock selector fork spring and remove retaining clips from each end of spring. (Scheme 84)
14. On all transfer boxes fitted with differential lock, 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, steel and felt washers; remove output shaft drive flange. (Scheme 85)
16. Using a copper mallet, drive output shaft from housing, recover bearing spacer. (Scheme 86)
17. If fitted, noting its fitted position, remove dog clutch from output shaft. (Scheme 86)
18. Remove and discard oil seal from housing. (Scheme 87)
19. Remove and discard circlip retaining output shaft bearing. (Scheme 87)
20. Support housing and drift out output shaft bearing. (Scheme 88)
21. Remove and discard differential bearing track and collect selective shim. (Scheme 89)
22. Remove plug securing high/low selector shaft detent spring and ball, remove spring and ball. (Scheme 90)
23. Withdraw differential assembly together with high/low selector shaft and fork. (Scheme 90)
24. Remove selector fork and shaft from differential. (Scheme 90)
25. Note position of shoulder bolt, remove 6 bolts and remove rear output shaft housing. (Scheme 91)
26. Remove rear bearing track from main casing.
27. Secure differential in a soft jawed vice.
28. Release staking from bearing retaining nut.
29. Using tool LRT-41-007 remove and discard bearing retaining nut. (Scheme 92)
30. Position tool LRT-99-002 to vice.
31. Position tool LRT-41-001 around rear differential bearing, position differential to tool LRT-99-002 and press off bearing. (Scheme 93)
32. Remove high range gear and bushing. (Scheme 94)
33. Make suitable alignment marks between high/low selector sleeve and hub, remove selector sleeve. (Scheme 94)
34. Using a suitable press and thrust button LRT-41-001 remove high/low hub and low range gear. (Scheme 95)
35. Position tool LRT-41-002 around front differential bearing and tool LRT-41-001 thrust button to differential shaft and press off bearing. (Scheme 96)

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Note. Numbers in illustration correspond to step numbers. (Scheme 97)

1. Secure rear half of differential carrier in a soft jawed vice.
2. Make suitable alignment marks between front and rear halves of differential carrier.
3. Remove 8 bolts securing front half of carrier to rear and separate both halves of carrier.
4. Suitably identify front sun gear to front half of carrier, then remove sun gear.
5. Remove and discard thrust washer.
6. Suitably identify each planet gear to its shaft and fitted position of each cross shaft to rear half of carrier.
7. Remove retaining ring.
8. Remove planet gears and cross shafts, remove and discard dished thrust washers.
9. Suitably identify rear sun gear to rear half of carrier, then remove sun gear.
10. Remove and discard thrust washer.

Scheme 97

Inspection

1. Check mating surfaces of cross shaft and housing bore for wear.
2. Check core plug in housing for signs of leakage or corrosion. Apply sealant, Part No. STC 3811 to replacement plug.
3. Measuring across widest portion of high/low selector finger. (Scheme 98) Check high/low selector finger for wear: Finger width = 15.90 to 15.95 mm (0.625 to 0.627").
4. Check bearing track recesses in housing for damage, rectify or replace housing as necessary.
5. If NOT fitted with differential lock, go to step 15. If fitted with differential lock, go to next step and carry out inspection of differential lock components using following procedures.
6. Check differential lock selector shaft and housing bore for wear.
7. Measuring across the widest portion, check differential lock finger for wear. (Scheme 99): Finger width = 15.90 to 15.95 mm (0.625 to 0.627").
8. Check differential lock selector finger groove in selector shaft. (Scheme 100): Groove width = 16.0 to 16.1 mm (0.63 to 0.64").
9. Check detent grooves in differential lock selector shaft for wear. (Scheme 101)
10. Check differential lock detent ball for flat spots and check detent spring for distortion.
11. Check differential lock selector fork for cracks and wear.
12. Check differential lock selector fork finger width. (Scheme 102): Finger width = 7.92 to 7.97 mm (0.311 to 0.313").
13. Check differential lock selector fork clips for wear and damage. Check spring for distortion and free length: Spring free length = 84.58 mm (3.33").
14. Check dog clutch internal teeth and grooves and teeth on output shaft for wear and damage. (Scheme 103) Check selector fork groove width: Groove width = 8.05 to 8.20 mm (0.32 to 0.33").
15. Carry out the following inspection procedures for ALL transfer boxes.
16. Check threads and splines of output shaft for damage and wear. Check dog clutch teeth on shaft for wear and damage.
17. On 2003 Model Year onwards, compress high/low selector fork spring and remove retaining clips from each end of spring, remove high/low selector shaft. (Scheme 104)
18. Check detent grooves in high/low selector shaft for wear. (Scheme 105) DO NOT remove fork from shaft unless either component is being renewed. If fork is removed from shaft, coat the threads of the set screw with sealant, Part No. STC 50552 prior to assembling.
19. Check width of high/low selector groove. (Scheme 105): Groove width = 16.0 to 16.1 mm (0.63 to 0.64").
20. Check high/low selector fork for cracks and wear. (Scheme 106) Check selector fork finger width: Finger width = 7.37 to 7.47 mm (0.290 to 0.294").
21. On 2003 Model Year onwards, check high/low selector fork clips for wear and damage. Check spring for distortion, check free length of spring: Spring free length = 75 mm (2.95").
22. Check differential sun and planet gears for wear, cracks and chipping of teeth.
23. Check cross shafts and recesses in both halves of differential carrier for damage and wear. ENSURE planet gears are retained with their respective shafts.
24. Check retaining ring for distortion.
25. Check differential splines for wear and damage.
26. Check high/low hub for cracks, chipping and uneven wear. (Scheme 107) Check width of selector fork groove: Groove width = 7.5-7.6 mm (0.295-0.30").
27. Check splines and teeth on high/low selector sleeve for uneven wear, cracks, damage and chipping.
28. Check teeth of high and low range gears for cracks, chipping and uneven wear.
29. Check high range gear bush for wear and damage.

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Reassembling

1. Lubricate all components with recommended oil and lightly oil the differential bolt threads.
2. Secure rear half of differential carrier in a soft jawed vice.
3. Fit each planet gear to its respective cross shaft, fit NEW dished thrust washer to each gear. (Scheme 108)
4. Fit cross shafts, planet gears and dished thrust washers in rear half of carrier. (Scheme 108) ENSURE that cross shafts are fitted correctly. DO NOT fit the sun gear into the rear half carrier at this stage.
5. Fit retaining ring. (Scheme 108)
6. Fit a 1.05 mm (0.04") thrust washer to sun gear from front half of carrier. (Scheme 108) Position gear in front half of carrier.
7. Ensuring that assembly marks are aligned, fit both halves of carrier together. (Scheme 108)
8. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 N.m (44 ft. lbs.). (Scheme 108)
9. Insert the front output shaft into the front half of the carrier and check that the gears rotate freely. (Scheme 109)
10. Fit output flange on to the splines of the output shaft, but DO NOT fit flange nut at this stage. (Scheme 109)
11. Fit transmission brake drum to output flange and secure the drum using 2 nuts. (Scheme 109)
12. Secure a length of cord around the drum and attach one end of the cord to a spring balance. (Scheme 109)
13. Pull on the spring balance and note the load at which the brake drum starts to turn. Used gears should rotate smoothly, while NEW gears will have a notchy feel as they rotate.
14. Compare the figure obtained with the following: Used gears = 0.45 kg (1.0 lb.). New gears = 1.72 kg (3.8 lbs.).
15. If the load to turn figure is below the specified limits, proceed as follows.
16. Remove the front output shaft and brake drum.
17. Remove the 8 bolts securing the two halves of the differential carrier.
18. Separate the differential carrier and remove the sun gear and thrust washer from the front half.
19. Select a thicker thrust washer from the range available. There are 5 different thrust washers are available, rising in increments of 0.10 mm (0.004") from 1.05-1.45 mm (0.04-0.06").
20. Repeat steps 7 to 19 as necessary until the load to turn figure is as specified.
21. When specified load to turn is obtained, proceed as follows.
22. Remove the front output shaft and brake drum.
23. Remove the 8 bolts securing the two halves of the differential carrier.
24. Separate the differential carrier and remove the sun gear and thrust washer from the front half. Retain the selected thrust washer with its sun gear.
25. Remove retaining ring, then remove the planet gears and cross shafts.
26. Fit a 1.05 mm (0.04") thrust washer to sun gear from rear half of carrier. Position gear in rear half of carrier. (Scheme 110)
27. Fit planet gears, cross shafts and dished thrust washers to rear half of carrier. Ensure that cross shafts are fitted correctly. Do not fit the sun gear into the rear half carrier at this stage. (Scheme 110)
28. Fit retaining ring. (Scheme 110)
29. Ensuring that assembly marks are aligned, fit both halves of carrier together. (Scheme 110)
30. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 N.m (44 ft. lbs.). (Scheme 110)
31. Invert the assembly in the vice, insert the rear output shaft into the rear half of the carrier and check that the gears rotate freely. (Scheme 111)
32. Fit output flange on to the splines of the output shaft, but do not fit flange nut at this stage.
33. Fit transmission brake drum to output flange and secure the drum using 2 nuts. (Scheme 111)
34. Carry out the load to turn check, using the same method as for the front half carrier. Record the shim thickness when the load to turn is correct.
35. Fit the sun gear and selected thickness shim to the front half carrier.
36. Ensuring that assembly marks are aligned, fit both halves of carrier together.
37. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 N.m (44 ft. lbs.).
38. With differential assembled, fit rear output shaft and brake drum, then check overall load to turn. This should be approximately the same as the combined load to turn figure of both front and rear half carriers: Used gears = 0.90 kg (2.0 lbs.). New gears = 3.44 kg (7.6 lbs.).

Scheme 108

Scheme 109

Scheme 110

Scheme 111

1. Clean differential components. Remove all traces of sealant from housings and bolts, differential lock warning lamp switches and detent plugs.
2. Lubricate components with transfer box oil.
3. Position differential in soft jawed vice and fit front bearing using tool LRT-41-008. (Scheme 112)
4. Invert differential in soft jawed vice, and fit low range gear with dog teeth facing uppermost. (Scheme 113)
5. Fit high/low hub ensuring that machined groove on hub teeth faces towards low range gear. (Scheme 113)
6. Fit high/low selector sleeve ensuring that alignment marks on hub and sleeve are together. (Scheme 113)
7. Fit bush to high range gear ensuring collar is uppermost. (Scheme 113)
8. Fit high range gear and bush onto shaft. (Scheme 113)
9. Fit NEW rear bearing using tool LRT-41-008. (Scheme 114)
10. Using tool LRT-41-007, fit NEW bearing retaining nut and tighten to 72 N.m (53 ft. lbs.). DO NOT stake nut at this stage. (Scheme 115)
11. Using feeler gauges, determine clearance between low range gear and high/low hub. (Scheme 116): Clearance = 0.0-0.15 mm (0.002-0.006").
12. If clearance is not as specified, fit a NEW low range gear and high/low hub and re-check.
13. Using feeler gauges, determine clearance between high range gear and high/low hub. (Scheme 117): Clearance = 0.05-0.15 mm (0.002-0.006").
14. If clearance is not as specified, fit NEW high range gear and high/low hub and re-check.
15. Using a suitable drift, stake collar of nut into differential shaft recess.
16. Using LRT-51-009, fit NEW rear bearing track into main casing. (Scheme 118)
17. Using a straight edge and feeler gauges, check that bearing track is recessed 1 mm (0.04") below outer face of main casing.
18. Apply sealant, Part No. STC 4600 to rear output shaft housing face.
19. Position housing to main casing.
20. Apply sealant, Part No. STC 50552 to bolt threads fit housing to main case, fit bolts and tighten by diagonal selection to 45 N.m (33 ft. lbs.).
21. On 2003 Model Year onwards, fit high/low selector fork and spring to high/low selector shaft, fit retaining clips.
22. Position high/low selector shaft and fork to differential ensuring that fingers of selector fork are located in selector sleeve.
23. Position differential assembly into main casing ensuring that splines of rear output shaft are engaged in differential.
24. Position NEW differential front bearing track ensuring that track is seated squarely.
25. Position tool LRT-41-014/3 onto main casing. (Scheme 119)
26. Screw tool LRT-41-014/4 into tapped hole in main casing and attach suitable Dial Test Indicator (DTI) to pillar. (Scheme 119)
27. Position stylus of gauge to setting block LRT-41-014/3 and zero gauge. (Scheme 119)
28. Position stylus onto front bearing outer track and record reading. (Scheme 120)
29. Taking care not to disturb bearing, position stylus on opposite side of bearing track and record reading.
30. Obtain average of the 2 readings and record figure.
31. Position depth block tool LRT-41-014/2 and cross bar tool LRT-41-014/1 to front output housing. (Scheme 121)
32. Position DTI to tool LRT-41-014/1 cross bar and zero Dial Test Indicator (DTI) on depth block.
33. Position DTI to cross bar and record reading obtained.
34. Using the formula - 3.05 mm (0.120") + B - A = D, where: A = Average of readings to differential front bearing outer track. B = Height difference recorded between depth block and cross bar. D = Thickness of shim required to give differential bearing pre-load of 0.05 mm (0.002").
35. From the resultant figure obtained, select appropriate thickness shim from the range available.
36. Shims are available from 2.00-3.25 mm (0.08-0.13") thickness, rising in increments of 0.05 mm (0.002").
37. Heat the front output housing to 100°C (212°F) and fit NEW output shaft bearing using tool LRT-41-011. (Scheme 122)
38. Allow housing to air cool.
39. Fit NEW bearing retaining circlip ensuring that circlip is fully seated.
40. Using tool LRT-41-012, fit NEW output shaft oil seal. Check that oil seal is just contacting circlip. (Scheme 123)
41. Position selected shim in front output housing and using tool LRT-54-003, fit NEW differential front bearing track. (Scheme 124)
42. Fit bearing spacer to output shaft with chamfer on spacer towards threaded end. (Scheme 125)
43. If fitted, fit dog clutch with flange on clutch facing towards splined end. (Scheme 125)
44. Using a copper mallet, drive output shaft into bearing. If not fitted with differential lock, go to step
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.
49. Apply sealant, Part No. STC 4600 to front output shaft housing.
50. Position front output shaft 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 N.m (33 ft. lbs.).
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. On 2003 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 2003 Model Year, fit bolts and tighten to 25 N.m (18 ft. lbs.).
59. Fit differential lock detent ball and spring.
60. Apply sealant, Part No. STC 50552 to threads of differential lock detent plug.
61. On 2003 Model Year onwards with differential lock, fit and tighten detent plug, then loosen 2 complete turns.
62. On 2003 Model Year onwards with differential lock, apply sealant, Part No. STC 50552 to threads of differential lock detent plug.
63. On 2003 Model Year onwards with differential lock, fit detent ball and spring.
64. On 2003 Model Year onwards with differential lock, fit differential lock detent plug and tighten until head of plug is level with face of output shaft housing. (Scheme 126)
65. On 2003 Model Year onwards with differential lock, using a straight edge, check that head of plug is correctly positioned, screw plug in or out as necessary. (Scheme 126)
66. On 2003 Model Year onwards with differential lock, lubricate and fit NEW "O" rings to differential lock selector housing.
67. On 2003 Model Year onwards with differential lock, fit selector housing, ensure selector finger is located in shaft recess.
68. On 2003 Model Year onwards, position cable bracket to selector housing.
69. Apply sealant, Part No. STC 50552 to threads of selector housing bolts, fit bolts and tighten to 25 N.m (18 ft. lbs.).
70. Up to 2003 Model Year with differential lock, fit nut to differential lock warning lamp switch with counterbore positioned towards switch head. The nut acts as a spacer to ensure that switch setting is correct. Always ensure that nut is fully tightened to switch head (no gap). (Scheme 127)
71. Apply sealant, Part No. STC 50552 to threads of differential warning lamp switch.
72. Position switch into front output housing until nut bottoms out on housing; tighten nut to 11 N.m (8 ft. lbs.).
73. On 2003 Model Year onwards with differential lock, fit NEW aluminum sealing washers to differential lock warning lamp switches.
74. On 2003 Model Year onwards with differential lock, apply sealant, Part No. STC 50552 to threads of switches.
75. On 2003 Model Year onwards with differential lock, fit switches and tighten to 25 N.m (18 ft. lbs.).
76. Fit output flange, NEW felt washer, steel washer and NEW retaining nut.
77. Using tool LRT-51-003 to restrain flange, tighten output flange nut to 162 N.m (119 ft. lbs.). (Scheme 128)
78. If fitted, operate differential lock selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft.
79. Up to 2003 Model Year with differential lock, screw plug in or out until setting is correct.
80. Fit high/low selector shaft detent ball and spring.
81. Apply sealant, Part No. STC 50552 to threads of high/low selector shaft detent plug.
82. Up to 2003 Model Year with differential lock, fit and tighten plug, then loosen 2 complete turns.
83. On 2003 Model Year onwards with differential lock, fit detent plug and tighten until head of plug is level with face of main casing. Using a straight edge, check that plug is correctly positioned; screw plug in or out as necessary. (Scheme 129)
84. On 2003 Model Year onwards with differential lock, operate high/low selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft.
85. Up to 2003 Model Year with differential lock, screw plug in or out until setting is correct.
86. Fit intermediate gear cluster. See «INTERMEDIATE GEAR ASSEMBLY»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Remove 6 bolts securing high/low cross shaft housing, multiplug bracket and selector cable bracket to front output shaft housing; remove brackets and housing. (Scheme 130)
2. Remove 7 bolts securing differential lock selector side cover, remove side cover. (Scheme 131)
3. On vehicles up to 2003 Model Year, note position of longest bolt and remove 8 bolts securing front output shaft housing to main casing and remove housing. (Scheme 132)
4. On vehicles up to 2003 Model Year, remove 3 bolts securing differential lock selector housing and remove housing. (Scheme 132)
5. On vehicles up to 2003 Model Year, remove and discard "O" rings from selector housing. (Scheme 132)
6. On vehicles up to 2003 Model Year, remove differential warning lamp switch and locknut. (Scheme 132)
7. On vehicles up to 2003 Model Year, remove Allen plug and remove differential lock detent spring and ball. (Scheme 132)
8. On vehicles 2003 Model Year onwards, remove 2 differential warning lamp switches and sealing washers. (Scheme 133)
9. On vehicles 2003 Model Year onwards, note position of longest bolt and remove 8 bolts securing front output shaft housing to main casing; remove housing. (Scheme 133)
10. On vehicles 2003 Model Year onwards, remove 3 bolts securing differential lock selector housing and bracket, remove housing. (Scheme 133)
11. On vehicles 2003 Model Year onwards, remove and discard "O" rings from selector housing. (Scheme 133)
12. On vehicles 2003 Model Year onwards, remove differential lock detent plug, recover spring and ball. (Scheme 133)
13. Compress differential lock selector fork spring and remove retaining clips from each end of spring. (Scheme 134)
14. Withdraw differential lock selector shaft from front output housing, recover spring and remove selector fork. (Scheme 134)
15. Position tool LRT-51-003 to output shaft drive flange, remove and discard nut. (Scheme 135)
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. (Scheme 136)
19. Noting its fitted position, remove dog clutch from output shaft. (Scheme 136)
20. Remove and discard oil seal from housing.

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Assembly

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 transfer box oil.
3. Using tool LRT-41-012, fit NEW output shaft oil seal. (Scheme 137)
4. Fit bearing spacer to output shaft with chamfer on spacer towards threaded end. (Scheme 138)
5. Fit dog clutch with flange on clutch facing towards splined end.
6. Using a copper mallet, drive output shaft into bearing.
7. Compress differential lock selector spring and fit selector fork.
8. Position selector fork to groove in dog clutch.
9. Fit differential lock 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.
10. Compress differential lock selector spring and fit retaining clips at each end of spring.
11. Apply sealant, Part No. STC 4600 to front output shaft housing.
12. Position housing ensuring that output shaft and dog clutch splines are correctly engaged.
13. Apply sealant, Part No. STC 50552 to threads of bolts.
14. Fit front output shaft housing bolts and tighten in a diagonal sequence to 45 N.m (33 ft. lbs.).
15. Apply sealant, Part No. STC 4600 to mating face of high/low selector housing.
16. Position high/low selector housing to front output housing ensuring that high/low selector finger is located in groove in selector shaft.
17. Position multiplug and selector cable brackets to high/low selector housing.
18. Apply sealant, Part No. STC 50552 to threads of high/low selector housing bolts.
19. Fit bolts and tighten to 25 N.m (18 ft. lbs.).
20. Fit differential lock detent ball and spring.
21. On vehicles up to 2003 Model Year, apply sealant, Part No. STC 50552 to threads of detent plug.
22. On vehicles up to 2003 Model Year, fit and tighten detent plug, then unscrew 2 complete turns.
23. On vehicles up to 2003 Model Year, apply sealant, Part No. STC 50552 to threads of differential lock detent plug.
24. Fit differential lock detent ball and spring.
25. Fit detent plug and tighten until head of plug is level with face of housing. (Scheme 139)
26. Using a suitable straight edge, check that head of plug is correctly positioned, screw plug in or out as necessary.
27. Lubricate and fit NEW "O" rings to differential lock selector housing.
28. Fit selector housing, ensure selector finger is located in shaft recess.
29. Position bracket to selector housing.
30. Apply sealant, Part No. STC 50552 to threads of selector housing bolts, fit bolts and tighten to 25 N.m (18 ft. lbs.).
31. Clean threads of differential lock warning lamp switch(es).
32. On vehicles up to 2003 Model Year, fit nut to switch head with counterbore positioned towards switch head. The nut acts as a spacer to ensure that switch setting is correct. Always ensure that nut is fully tightened to switch head (no gap). (Scheme 140)
33. On vehicles up to 2003 Model Year, apply sealant, Part No. STC 50552 to threads of differential warning lamp switch.
34. On vehicles up to 2003 Model Year, position switch into front output housing until nut bottoms out on housing, tighten nut to 11 N.m (8 ft. lbs.).
35. On vehicles 2003 Model Year onwards, fit NEW aluminum sealing washers to differential lock warning lamp switches.
36. On vehicles 2003 Model Year onwards, apply sealant, Part No. STC 50552 to threads of both switches.
37. On vehicles 2003 Model Year onwards, fit switches and tighten to 25 N.m (18 ft. lbs.).
38. If fitted, operate differential lock selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft.
39. On vehicles up to 2003 Model Year, screw plug in or out until setting is correct. (Scheme 139)
40. Apply sealant, Part No. STC 4600 to mating face of differential lock selector side cover.
41. Apply sealant, Part No. STC 50552 to threads of side cover bolts.
42. Position differential lock selector side cover to front output shaft housing, fit bolts and tighten 25 N.m (18 ft. lbs.).
43. Fit output flange, NEW felt and steel washers and NEW retaining nut.
44. Using tool LRT-51-003 to restrain flange, tighten output flange nut to 162 N.m (119 ft. lbs.). (Scheme 141)

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

1. Make alignment marks between cover plate/bearing housing and main casing. (Scheme 142)
2. Remove 5 bolts and stud nut securing cover/bearing housing to main casing. Remove cover and bearing housing. (Scheme 142)
3. Remove input gear assembly. (Scheme 143)
4. Remove and discard oil seal from main casing. (Scheme 144)
5. Drift out bearing track from main casing. (Scheme 145)
6. Drift out bearing track from housing and collect selective shim. (Scheme 146)
7. Position tool LRT-99-002 to vice. (Scheme 147)
8. Assemble tool LRT-41-003 to bearing, position input gear to hand press and remove bearing. (Scheme 147)
9. Repeat procedure for remaining bearing.

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

1. Clean input gear, cover/bearing housing and main casing.
2. Using tool LRT-99-002 and LRT-41-003 fit NEW bearings to input gear. (Scheme 148)
3. Using a suitable mandrel, fit bearing track to main casing.
4. Fit a 3.15 mm (0.12") thick shim to bearing housing and using a suitable mandrel fit bearing track to housing.
5. Position input gear to main casing.
6. Fit bearing housing, ensuring reference marks are aligned, secure bearing housing with 2 bolts and tighten to 25 N.m (18 ft. lbs.). (Scheme 149)
7. Position dial gauge with stylus contacting input gear, push input gear rearwards and zero gauge.
8. Push input gear forwards and note gauge reading.
9. Calculate thickness of shim required using the formula - A + B + C = D where: A = Thickness of installed shim - 3.15 mm (0.12"). B = Recorded end-float. C = Required pre-load - 0.05 mm (0.002"). D = Thickness of shim required.
10. If an alternative shim is required to establish correct pre-load, fit an alternative shim. Shims are available from 3.15-4.00 mm (0.12-0.16") thickness, in increments of 0.05 mm (0.002").
11. Remove 2 bolts, remove bearing housing and input gear.
12. Lubricate input gear and bearings with recommended oil.
13. Position input gear into main casing.
14. Apply sealant, Part No. STC 4600 to bearing housing and cover.
15. Apply sealant, Part No. STC 50552 to threads of cover bolts and stud nut.
16. Position bearing housing/cover, align reference marks and tighten bolts and stud nut by diagonal selection to 45 N.m (33 ft. lbs.).
17. Using tool LRT-37-014 fit NEW input shaft oil seal. (Scheme 150)

Scheme 148

Scheme 149

Scheme 150

1. Remove differential. See «DIFFERENTIAL ASSEMBLY»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).
2. Secure differential in a soft jawed vice.
3. Release staking from bearing retaining nut. (Scheme 151)
4. Using tool LRT-41-007 remove and discard bearing retaining nut.
5. Position tool LRT-99-002 to a vice. (Scheme 152)
6. Position tool LRT-41-001 around rear differential bearing, position differential to tool LRT-99-002 and press off bearing. (Scheme 152)
7. Remove high range gear and bush. (Scheme 153)
8. Make suitable alignment marks between high/low selector sleeve and hub, remove selector sleeve. (Scheme 153)
9. Using a suitable press and thrust button LRT-41-001 remove high/low hub and low range gear. (Scheme 154)

Scheme 151

Scheme 152

Scheme 153

Scheme 154

1. Clean differential components.
2. Lubricate components with transfer box oil.
3. Fit differential in soft jawed vice, and fit low range gear with dog teeth facing uppermost.
4. Fit high/low hub ensuring that machined groove on hub teeth faces towards low range gear.
5. Fit high/low selector sleeve ensuring that alignment marks on hub and sleeve are together.
6. Fit bush to high range gear ensuring collar is uppermost.
7. Fit high range gear and bush onto shaft.
8. Fit rear bearing using tool LRT-41-008. (Scheme 155)
9. Fit NEW bearing retaining nut and using tool LRT-41-007, tighten to 72 N.m (53 ft. lbs.). (Scheme 156)
10. Using a suitable drift, stake collar of nut into differential shaft recess.
11. Fit differential. See «DIFFERENTIAL ASSEMBLY»(/land-rover/discovery/l318-2002-2004/remont/transfer-case/#overhaul-transfer-case-lt230se).

Scheme 155

Scheme 156

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL DATA

See also:
• DRIVE SHAFT - FRONT
• LUBRICATION SPECIFICATIONS
• TRANSFER BOX DRAIN & REFILL
• CABLE - HIGH/LOW SELECTOR
• CHECK/TOP-UP OIL LEVEL