drain bolt LAND ROVER DISCOVERY 1995 Service Owner's Guide

Mpi
1
REPAIR COOLANT PUMP
Service repair no - 26.50.01
Remove
1.Position drain tin below coolant pump hose.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Release clip and disconnect hose from coolant
pump housing cover.
3.Remove 5 bolts securing housing cover.
4.Remove housing cover.
5.Remove coolant pump from housing.
6.Discard 3 sealing rings.
Refit
7.Clean coolant pump housing and mating faces.
8.Lubricate new sealing rings with Loctite 405 and
fit to coolant pump.
9.Fit coolant pump to housing.
10.Position housing cover, fit 5 bolts. Tighten to
25Nm
11.Connect hose to housing cover and tighten clip.
12.Refill cooling system.

26COOLING SYSTEM
2
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect battery negative lead.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Slacken clip and release bottom hose from
radiator, allow coolant to drain into a suitable
container
3.Slacken clip and release bottom hose from
radiator rail.
4.Slacken clip and release top hose from radiator.
5.Release air cleaner to throttle housing hose from
securing brackets.
6.Slacken clip and release bypass hose from
radiator.
7.Slacken clip and release top expansion hose
from radiator.
8.Remove 2 bolts securing radiator side support
brackets.
9.Collect L.H. support bracket and position R.H.
support bracket aside.
10.Slacken clip and release heater hose from
radiator rail.
11.Disconnect 2 multiplugs from cooling fan
assemblies.

R380
1
REPAIR R380 MANUAL GEARBOX
Service repair no - 37.20.02
Remove
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer's instructions to ensure safe and
effective use of equipment.
1.Install vehicle on a ramp [hoist].
2.Disconnect battery earth lead.
3.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
4.Remove sound insulation from top of
transmission tunnel.
5.Remove bolt and remove upper gear lever.
6.Remove screws securing gear selector lever and
high/low selector lever draft excluders.
7.Remove draft excluder clamp rings.
8.Remove handbrake cable clevis pin clip and
clevis pin.
9.Remove 'C' clip and cable adjuster.
10.Select low range to prevent gear lever fouling
tunnel when removing gearbox.
11.Remove bolt securing gearbox breather pipe clip
to cylinder block.
12.Remove bolts securing fan cowl to radiator.
13.Release fan cowl from radiator and lay over fan
blades.
14.Raise ramp [hoist].
15.Drain oil from main gearbox and transfer
gearbox.
See SECTION 10, Maintenance,
Under Vehicle Maintenance
16.Remove exhaust front pipe(s).See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
System Complete
17.Release intermediate exhaust pipe(s) from
mountings and tie aside.
18.Remove bolts securing clutch slave cylinder.
19.Release slave cylinder from clutch housing and
collect spacer.
20.Mark propeller shaft drive flange relationships for
reassembly.
21.Disconnect front and rear propeller shafts from
transfer gearbox. Tie shafts aside.
22.Remove clamp and disconnect speedometer
cable from transfer gearbox.
23.Release handbrake cable from transmission
tunnel.
24.Temporarily support transmission in a way which
enables the crossmember to be removed and a
hoist cradle to be fitted.

41TRANSFER GEARBOX
2
FAULT DIAGNOSIS PROCEDURE
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
the system the pipe must be removed,
inspected, rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
5.Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1.Drain the oil and remove the leaking output
flange.
2.Inspect the seal track on the flange for surface
damage. If damaged renew component.
3.Remove and discard the oil seal.
4.Inspect the seal locating bore and remove any
sharp edges which may damage the new oil
seal.
5.Fit new seal.
6.Fit the output flange and all the other parts.
7.Add oil to correct level into the gearbox.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
Cover plate gasket leaking.
1.Drain the oil and remove the leaking cover plate.
2.Remove all traces of joint sealant from both joint
faces.
3.Degrease all components and apply a thin film of
Hylomar sealant, to both joint faces.
4.Apply thread sealant to the bolts which come
into contact with gearbox oil.
5.Refit cover plate.
CAUTION: Care must be taken not to
overtighten the fixings.Leak between the main and transfer gearboxes.
1.Site vehicle onto a ramp [hoist].
2.Select neutral in transfer box and select 4th gear
in the main gearbox.
3.Run engine at 2000 rpm with the clutch/drive
engaged.
4.Observe joint between the main and transfer
boxes.
5.If oil leak is found establish if it is gear oil.
6.If so, the leak is originating from the transfer box.
7.Check the two inner (main/transfer) bolts are oil
tight, as these holes are tapped through into the
main transfer case.
8.Remove the transfer box to inspect the
mainshaft collar seal track condition, and the
front face of the transfer case for porosity.
See
Repair, LT230T Transfer Gearbox
9.If these areas require servicing, the transfer
gearbox input seal must also be renewed.
CAUTION: Avoid damaging the new seal
lip and ensure the seal is fitted flush with
the machined face. Also ensure the new
seal is not damaged when refitting the transfer
gearbox.
10.If red A.T.F type oil is seen leaking during the
workshop test, investigate the main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1.Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in the transfer case and
therefore should be considered when looking for
the source of the leak.

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

TRANSFER GEARBOX
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
LT230T Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................
Shiftlock
Shiftlock screws 9..........................................................................................
Neutral switch 25............................................................................................

ZF
5
REPAIR Remove
1.Select low range with transfer gear lever.
2.Remove knob and gaiter from transfer gear
lever.
3.Disconnect battery terminals.
4.Remove insulation pad from rocker cover and
inlet manifold.
5.On LH drive vehicles only, disconnect multi-plug
from top of brake fluid reservoir.
6.Release electrical harness from clips along top
of bulkhead and pull over to one side.7.Remove bolt securing transfer and main gearbox
breather pipe clip to rear of cylinder head.
8.Disconnect kick down cable at fuel injection
pump.
9.Drain coolant from cooling system.
10.Disconnect top hose from radiator.
11.Disconnect turbo charger hose from inter-cooler.
12.Remove starter heat shield.

44AUTOMATIC GEARBOX
6
REPAIR 13.Remove starter.
14.Working through starter aperture note position of
torque converter flexible drive plate to facilitate
refitting.
15.Remove the four torque convertor to flexible
drive securing bolts, rotating engine to gain
access to each individual bolt.
16.Raise vehicle on four post ramp [hoist].
17.Drain lubrication oil from transfer and main
gearboxes.
18.Disconnect speedometer cable from transfer
gearbox and disconnect associated clipping.
19.Remove rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
20.Disconnect front propeller shaft at transfer
gearbox and tie to one side.
21.Remove exhaust front pipe.
22.Remove bolts securing front and centre silencer
mounting brackets and tie silencer to one side.
23.Disconnect oil cooler pipes from gearbox.
24.Blank off pipes and union connections.
25.Remove bolt securing retaining bracket to sump
and move cooler pipes aside.
26.Disconnect selector cable from lever on side of
gearbox.
27.Disconnect inhibitor switch multi-plug.
28.Disconnect park brake cable from linkage to park
brake lever.
29.Disconnect electrical connections from
differential lock switch on transfer gearbox.
30.Remove two lower bolts from transfer gearbox
input bearing support plate.
31.Assemble approved support cradle to
transmission hoist.32.Raise hoist and secure cradle to transfer
gearbox input bearing support plate using bolts
removed.
33.Disconnect gearbox mounting brackets from
chassis cross member.
34.Remove chassis cross member.
35.Lower transmission sufficiently to allow access
to items attached to top of gearbox.
36.Remove left hand gearbox mounting bracket
assembly.
37.Remove ties from breather pipes and harness.
38.Remove nut securing gearbox oil filler/dip stick
tube to bell housing.
39.Release union nut at gearbox sump and remove
filler/dipstick tube. Fit blanking plugs.
40.Support engine using a wooden block with a
suitable ramp [hoist] jack.
41.Remove nut securing kick down cable bracket to
bell housing.
42.Remove two bolts securing top of bell housing to
flywheel housing.
43.Remove nuts securing bell housing to flywheel
housing and withdraw transmission assembly
from engine.
44.Fit a suitable torque converter retaining strap to
the bell housing.
45.Remove hoist and transmission from under
vehicle.
46.Fit lifting eyes to transmission.
47.Using suitable chains and lifting tackle take
weight of transmission assembly.
48.Remove bolts securing transmission cradle to
transfer box and withdraw hoist complete with
cradle.
49.Refit bolts to cover plate.

ZF
9
REPAIR OIL SUMP
Service repair no - 44.24.05
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.Refit
12.Refit oil sump using a new gasket.
13.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
14.Refit chassis cross member.
15.Refit catalytic converter assembly
16.Connect electrics to Lambda sensors.
17.Connect heat shield front pipe to manifold.
18.Connect battery.
19.Refill gearbox using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

44AUTOMATIC GEARBOX
10
REPAIR OIL SCREEN
Service repair no - 44.24.07
Renew
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard 'O' ring seal.13.Detach suction pipe from oil screen, discard 'O'
ring seal.
14.Clean oil screen and blow out with airline.
15.Clean suction pipe.
16.Fit new 'O' ring seals to oil screen using light
grease to aid assembly.
17.Fit oil screen and suction pipe with spacer and
secure with three bolts.
18.Refit oil sump using a new gasket.
19.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
20.Refit chassis cross-member.
21.Refit catalytic converter assembly
22.Connect electrics to Lambda sensors.
23.Connect heat shield front pipe to manifold.
24.Connect battery.
25.Refill gearbox oil system using correct grade of
oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids