Transfer Gearbox - Whine
20/1/9541/01/95/US
SUBJECT:
LT230t Transfer Gearbox Whine
MODEL:
Discovery
AFFECTED VEHICLES:
All 94 MY Manual and Automatic - Early 95 MY
DETAIL
Investigations by Land Rover engineers have found that a good proportion of transfer gearbox whine can be "tuned" out by fitting a modified transfer gearbox lever and knob. The modification includes the fitment of an attenuated (damped) gearlever and "heavy" transfer gearlever knob. Work is continuing to quieten the noise at source but significant noise reduction can be achieved by fitment of the kit noted.
This modification was introduced onto production at VIN LJ 126065. Approximately 1500 vehicles before this VIN were updated to the new condition prior to delivery, either at the Port of entry or by you the dealer, if the vehicle was in your stock. On customer complaint only, follow the procedure below
ACTION REQUIRED
On customer complaint of transfer box whine, check to see if the vehicle has a "heavy" high/low shift knob. Gauge the weight of the knob. Alternatively, by accessing the lower region of the high/low shift lever through the Center console aperture, check to see whether the attenuation bulge can be felt. If the heavy knob and attenuated lever is not fitted order the kit below and follow the fitting procedure
PARTS INFORMATION
STC 2915K gear lever kit
Windscreen adhesive or black RTV
Manual Vehicles
Note:
For early gear lever kits to update a manual transmission vehicle, you will need to get locally 6, 3/16" diameter 1/2" reach rivets in addition to what is supplied in the kit above. Later kits will have sufficient rivets supplied.
WARRANTY
Normal warranty policy and procedures apply.
COMP. CODE: 3J5W
SRO: 41.10.89/26 Fit new gearlever and knob - 01.10 hour
PROCEDURE
1) Disconnect negative battery lead.
2) Remove Transfer Box Hi/Lo shifter boot from center console.
3) Unscrew Transfer Box Hi/Lo shift knob from lever.
4) Remove shift knob from boot by turning boot inside out. Remove knob from boot by removing O-ring and discard old knob. Replace with new knob supplied in kit.
5) Remove center console assembly as per Section 76 page 50 of the Discovery Workshop Manual.
6) Loosen 2 screws securing heater vents and remove heater ducts.
7) Cover heater vents and ducts to prevent debris from falling in.
8) Remove front console bracket. (2 screws).
9) Remove sound deadening pad.
10) Drill out the 8 pop rivets (14 on manual transmission) securing lower boot retainer plate. Use a 7/32" (5mm) drill. Care must be taken when drilling out rivets not to damage the body. A right angle drill is recommended when drilling out 3 forward most rivets.
11) Remove Hi/Lo shift lever housing boot and retainer plate.
12) Remove Diff lock lever dip and Clevis pin.
13) Remove 4 mounting bolts holding shift lever box to transmission.
14) Mark position of splined Hi/LO shifter lever arm and remove by loosening the clamp bolt.
15) Remove Shifter housing from vehicle and take to worktable space. (Save Gasket for reinstallation).
16) Remove shifter housing boot, uppermost retainer plate and lower gate plate. (4 bolts) DISCARD THE BOOT AND UPPERMOST SEAL RETAINING PLATE.
17) Remove retaining clip and Clevis pin from bottom end of shifter arm. Take care not to loose the nylon bushings.
18) Remove circlip securing nylon seat on shifter assembly
19) Remove lever assembly and discard.
20) Grease new lever ball pivot.
21) Fit new lever (ensure bend in shifter ann will face towards front of vehicle).
22) Refit Circlip to nylon seat on shifter assembly pivot point.
23) Refit nylon bushings, Clevis pin, and retaining clip to bottom end of shifter.
24) Refit the Hi/Lo lever gate plate using the 4 bolts.
DO NOT Refit the shifter housing gaiter and uppermost retainer plate.
25) Return shifter housing to vehicle.
26) Refit the splined Hi/LO shifter lever arm and tighten the clamp bolt - Align the marks.
27) Refit shifter box and gasket to transmission. Take care to ensure mating surfaces are clean.
28) Refit 4 bolts.
29) Refit Diff lock lever Clevis pin and retaining dip.
30) Refit body boot to body using windscreen adhesive or black RTV to seal boot to body.
(It is essential to achieve the maximum effectiveness of this kit that this sealing is carried out and a good seal is generated between body and boot.)
31) Refit boot retaining plate and secure with rivets.
32) Refit sound deadening pad.
33) Remove covers from the heater ducts and refit heater ducts and tighten retaining screws.
34) Refit center console and shifter knob as per Section 76 page 50 of the Discovery Workshop Manual. Take care not to trap the seat belt stalks when reinstalling the console.
35) Reconnect battery. TEST DRIVE VEHICLE.
Note:
When reassembling the console ensure that there are no loose harnesses that could get trapped/pinched, or cause rattles.