ECU LAND ROVER DISCOVERY 1999 Workshop Manual

MANUAL GEARBOX - R380
37-38 OVERHAUL
Extension - gearbox rear
$% 37.12.01
Disassembly
1.Remove 4 bolts and remove gear selector
housing.
2.Using tools LRT-37-009, LRT-37-001/2 and
LRT-37-010 , remove output shaft oil seal
collar.3.Remove bolt securing interlock spool retainer
and discard 'O' ring.
4.Noting fitted position of 2 longest bolts, remove
10 bolts securing extension housing to
gearbox.
5.Remove extension housing from gearbox
centre plate.

MANUAL GEARBOX - R380
OVERHAUL 37-39
6.Fit 2 off 8x35 mm slave bolts to secure centre
plate to gearbox casing.
7.Remove 3 Torx screws, remove oil pump and
discard 'O' ring.
8.Drift out layshaft support bearing.
9.Remove and discard output shaft rear oil seal.
10.Remove oil pick-up pipe. 11.Drift out output shaft support bearing and oil
pick-up ring.
12.Remove reverse inhibitor shaft, cam and
spring.
13.Remove 2 bolts and remove gate plate.
14.Remove reverse light switch and discard
sealing washer.
15.Remove 2 bolts, remove oil cooler by-pass and
discard 'O' rings.
Reassembly
1.Clean extension housing and mating faces.
2.Clean oil cooler by-pass.
3.Using new 'O' rings, fit oil cooler by-pass and
tighten bolts to 15 Nm (11 lbf.ft).
4.Using new sealing washer, fit reverse light
switch and tighten to 24 Nm (17 lbf.ft).
5.Fit reverse inhibitor spring and cam.
6.Clean threads of reverse inhibitor shaft and
gate plate bolts.
7.Apply sealant, Part No. STC 50552 to threads
of reverse inhibitor shaft, fit and tighten shaft.
8.Apply sealant, Part No. STC 50552 to threads
of gate plate bolts.
9.Position gate plate and tighten bolts to 15 Nm
(11 lbf.ft).
10.Fit output shaft support bearing and oil pick-up
ring. Align tag with centre of drain slot.
11.Fit layshaft support bearing.

MANUAL GEARBOX - R380
37-40 OVERHAUL
12.Fit new output shaft oil seal using tool LRT-37-
014.
13.Fit oil pick-up pipe with the off-set uppermost.
14.Lubricate oil pump recess with gearbox oil.
15.Lubricate a new 'O' ring with gearbox oil and fit
to oil pump.
16.Locate oil pump in extension housing with word
'TOP' towards top of housing.
17.Align oil pump fixing screw holes and tap pump
lightly around edges until it is fully in recess.
Do not attempt to pull pump into recess
using fixing screws.
18.Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
19.Remove 2 slave bolts securing centre plate to
gearbox casing.
20.Apply sealant, Part No. STC 4404 to gearbox
casing face.
21.Position extension housing, align oil pump drive
with layshaft.
22.Clean extension housing bolt threads.
23.Apply sealant, Part No. STC 50552 to threads
of extension housing bolts, fit bolts ensuring 2
longest bolts are in their original positions and
tighten by diagonal selection to 25 Nm (18
lbf.ft).
24.Using new 'O' ring, fit interlock spool retainer
and tighten bolt to 8 Nm (6 lbf.ft). 25.Using tool LRT-37-015 and LRT-37-021, fit oil
seal collar.
26.Clean gear selector selector housing and
mating face.
27.Apply sealant, Part No. STC 4404 to gear
selector housing face.
28.Position gear selector housing and tighten
bolts to 25 Nm (18 lbf.ft).

MANUAL GEARBOX - R380
OVERHAUL 37-43
Synchronizer assembly - 5th/reverse
$% 37.20.38
Disassembly
1.Remove gearbox rear extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove 5th gear set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Gear - 5th gear set.
3.Remove split needle roller bearing from output
shaft.
4.Remove and discard Allen screw and remove
gear change yoke.
5.Remove and discard circlip securing 5th/
reverse synchronizer hub to output shaft.
6.Remove synchronizer hub and selector fork
assembly. Reassembly
1.Clean gears, shafts, bearings and selector
fork.
2.Position selector fork to synchronizer, fit
assembly to output shaft and selector shaft. Fit
new hub retaining circlip.The fit of the circlip
is controlled by the selective washer behind
the reverse gear bearing collar on the
output shaft.
3. Adjust to give a reverse gear end-float of
0.005 - 0.055mm (0.0002 - 0.0021in).
4.Apply sealant, Part No. STC 50552 to threads
of new gear change lever yoke Allen screw.
5.Position gear change lever yoke and tighten
Allen screw to 25 Nm (18 lbf.ft).
6.Position split needle roller bearing to output
shaft.
7.Fit 5th gear set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Gear - 5th gear set.
8.Fit gearbox rear extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380
37-44 OVERHAUL
5th gear - layshaft
$% 37.20.43
Disassembly
1.Remove gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Using a suitable two legged puller and remove
5th gear layshaft support bearing track from
end of layshaft.
3.Release staking from 5th gear retaining nut. 4.Using tool LRT-37-023 to hold 5th gear,
remove and discard stake nut.
5.Remove retaining ring and split collars
securing 5th gear to output shaft.

MANUAL GEARBOX - R380
OVERHAUL 37-45
6.Remove split collar and 5th gear from layshaft. Reassembly
1.Clean gear and layshaft.
2.Position 5th gear and split collar to layshaft
ensuring that bevelled side of collar is towards
5th gear.
3.Position split collars and retaining ring securing
5th gear to output shaft.
4.Position tool LRT-37-023 to hold 5th gear and
tighten new stake nut to 220 Nm (162 lbf.ft) and
stake nut.
5.Apply a small amount of heat and fit support
bearing track to layshaft.
6.Fit gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380
OVERHAUL 37-49
5.Remove 2 bolts securing spool retainer to
gearbox case. Remove retainer, remove and
discard 'O' ring - if fitted.
6.Remove interlock spool from selector shaft.
7.Remove filter from gearbox case.
8.Align selector shaft pin with slot in centre plate
and using wooden blocks and hide mallet,
release centre plate and collect lower detent
ball and spring. 9.Press out reverse idler shaft using a suitable
press.
10.Remove idler gear, needle roller bearing and
spacer.

MANUAL GEARBOX - R380
OVERHAUL 37-51
Lever - gear change
$% 37.16.04
Disassembly
1.Remove gear selector housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
2.Restrain right hand bias spring using a suitable
pair of grips.
3.Remove 2 bolts securing right hand side of bias
spring adjustment plate.
4.Repeat operations for left hand bias spring.
5.Remove bias springs and adjustment plate.6.Remove lower gear lever.
7.Remove and discard Railko bush.
8.Remove and discard oil seal from housing.

MANUAL GEARBOX - R380
37-52 OVERHAUL
Reassembly
1.Clean components.
2.Apply multi-purpose grease to ball and cross
pins.
3.Apply multi-purpose to new Railko bush and fit
to housing ensuring that slots are correctly
aligned.
4.Lubricate a new seal with gearbox oil and fit, lip
side towards housing using a suitable mandrel.
5.Position lower gear lever to selector housing
ensuring cross pins are located in Railko bush.
6.Position bias spring adjustment plate to
selector housing.
7.Clean threads of bias spring adjustment plate
bolts and apply sealant, Part No. STC 50552 to
threads.
8.Fit 2 short bolts to secure front of adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9.Position right hand bias spring to pillar ensuring
longest end of spring is against gear lever.
10.Restrain bias spring using a suitable pair of
grips, ensure shortest end of spring is on
outside edge of bolt hole.
11.Fit longest bolt and washer ensuring end of
bias spring is under washer, tighten bolt to 25
Nm (18 lbf.ft).
12.Repeat above procedures for remaining bias
spring.
13.Fit gear selector housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
14.Adjust gear lever bias springs.

+ MANUAL GEARBOX - R380,
ADJUSTMENTS, Spring - gear lever bias.
Housing - clutch
$% 37.12.07
Disassembly
1.Remove clutch release bearing and operating
lever.
2.Remove 6 bolts and remove clutch housing.
Reassembly
1.Clean clutch housing and gearbox mating face.
2.Position clutch housing and tighten bolts to 75
Nm (55 lbf.ft).
3.Fit clutch operating lever and release bearing.

MANUAL GEARBOX - R380
OVERHAUL 37-53
Cover - front
$% 37.12.33.01
Disassembly
1.Remove retaining peg and remove release
bearing.
2.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
3.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 4.Remove 6 bolts securing clutch housing and
remove clutch housing.
5.Remove and discard 6 bolts securing oil seal
housing.
6.Remove oil seal housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing, discard seal.