gearbox LAND ROVER DISCOVERY 1995 Service Repair Manual

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Workshop manual
DISCOVERY
This manual covers vehicles from
1995 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE Tdi
12 ENGINE 3.9 V8
12 ENGINE 4.0 V8
12 ENGINE Mpi
17 EMISSION CONTROL
19 FUEL SYSTEM Tdi
19 FUEL SYSTEM MFI
19 FUEL SYSTEM SFI
19 FUEL SYSTEM Mpi
19 CRUISE CONTROL
26 COOLING SYSTEM Tdi
26 COOLING SYSTEM V8
26 COOLING SYSTEM Mpi
30 MANIFOLD AND EXHAUST SYSTEM
33 CLUTCH
37 MANUAL GEARBOX
41 TRANSFER GEARBOX
44 AUTOMATIC GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
75 SUPPLEMENTARY RESTRAINT SYSTEM
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
Published by Rover Technical Communication
Ó1996 Rover Group Limited
Publication Part No. LRL 0079 ENG (2nd Edition)

INTRODUCTION
1
INFORMATION INTRODUCTION
This workshop manual covers vehicles from 1995
model year onwards. Amendments and additional
pages will be issued to ensure that the manual
covers latest models. Amendments and additions
will be identified by the addition of a dated footer
at the bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which could not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Land
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONSandNOTESare given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents, shown in
brackets following the dimensions, have been
converted from the original specification.REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
water pump end of the engine is referred to as the
front.
To reduce repetition, some operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturer's specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.

INTRODUCTION
5
INFORMATION JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1.Use a solid level ground surface.
2.Apply parking brake.
3.Select 'P' or 1st gear in main gearbox.
4.Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure
Bumpers
Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bell housing
Jack or support vehicle by axles only.Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOTuse the jack for any other purpose. Refer to
Owner's Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used.
CAUTION: Do not commence work on the
underside of the vehicle until suitable axle
stands have been positioned under the
axle.
Raise the front of the vehicle
1.Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.

01INTRODUCTION
6
INFORMATION 2.Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3.Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1.Position cup of hydraulic arm under differential
casing.
2.Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3.Lower jack until axle sits securely on axle
stands, remove trolley jack.
4.Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5.Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a 'drive on' type ramp which supports vehicle
by its own road wheels. If a 'wheel-free' condition is
required, use a 'drive on' ramp incorporating a
'wheel-free' system that supports under axle casings.
Alternatively, place vehicle on a firm, flat floor and
support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using 'Two Post' ramps
that employ four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If vehicle is installed on a Two Post ramp
responsibility for safety of vehicle and personnel
performing service operations is in the hands of
the Service Provider.DYNAMOMETER TESTING - NON ANTI-LOCK
BRAKE VEHICLES
Viscous coupling
The front and rear axles cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively locking the centre differential
automatically if slip occurs at any wheel.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.

INTRODUCTION
7
INFORMATION DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the valve
relay.
See Electrical Trouble Shooting
Manual.
The ABS function will not work, the ABS warning
light will illuminate. Normal braking will be
available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary it must be
carried out with propeller shaft to the rear axle
removed, AND neutral selected in BOTH main and
transfer boxes.
If checking engine performance, the transfer box must
be in high range and drive shaft to stationary axle
removed.
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1.Turn ignition key turn to position '1' to release
steering lock.
2.Select neutral in main gearbox and transfer
gearbox.
3.Secure tow rope, chain or cable to towing eye.
4.Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, 'snatch' recovery
should be avoided.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
front or rear propeller shaft MUST BE
removed, dependent upon which axle is
being trailed.
1.Mark propeller shaft drive flanges at transfer
gearbox and axles with identification lines to
enable the propeller shaft to be refitted in its
original position.
2.Remove the propeller shaft fixings, remove the
shaft from the vehicle.
3.If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.

01INTRODUCTION
8
INFORMATION TRANSPORTING THE VEHICLE BY TRAILER
Lashing eyes are provided on front and rear of the
chassis side members, to facilitate the securing of the
vehicle to a trailer or other means of transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
neutral in main gearbox. Selecting 'N' will prevent
damage to parking pawl of the automatic gearbox.
FRONT OF CHASSIS
REAR OF CHASSIS
JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1.Position vehicles so that jump leads will reach,
ensuring that vehiclesDO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2.Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected on a manual
gearbox, with an automatic gearbox select
neutral (N) or park (P) and then connect the
jump leads as follows;
A.Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B.Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C.Connect one end of second jumper cable to
negative terminal of booster battery.

01INTRODUCTION
14
INFORMATION LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - 300Tdi Engine
The 300Tdi engine number is stamped on the cylinder
block on the right hand side of the engine above the
camshaft front cover plate.
Engine serial number - Mpi engine
Stamped on the R.H. face of the cylinder block
adjacent to the gearbox.
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The appropriate engine
compression ratio is stamped above the
serial number.
Main gearbox R380
Stamped on a cast pad on the bottom right hand side
of the gearbox.
Transfer gearbox LT230
The serial number is stamped on the left hand side of
the gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover.
Front and rear axles
Serial number is stamped on top of the left hand axle
tube.

INTRODUCTION
15
INFORMATION Automatic gearbox
Stamped on a plate riveted to the bottom left hand
side of the gearbox casing.

GENERAL SPECIFICATION DATA
9
INFORMATION TRANSMISSION 3.9 V8i
Manual gearbox
Type R380 Single helical constant mesh.......................................................................
Speeds 5 forward 1 reverse all synchromesh.............................................................................
Clutch
Make and type Borg and beck diaphram type..................................................................
Clutch plate diameter 266.5mm........................................................
Automatic gearbox
Type ZF4HP Four speed and reverse with fluid torque converter.....................................................................
Transfer box
Type LT230T Two speed reduction on main gearbox output, front....................................................................
and rear drive permanently engaged via a lockable
differential.
Propeller shafts
Type
Front Tubular 51mm diameter.................................................................................
Front - Catalyst vehicles Solid bar 28.6mm diameter...................................................
Rear Tubular 51mm diameter.................................................................................
Universal joints Open type Hookes O3EHD.................................................................
Rear axle
Type Spiral bevel, fully floating shafts.................................................................................
Ratio 3.54:1.................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully.................................................................................
floating shafts
Angularity of universal joint on full lock 32° ............................
Ratio 3.54:1.................................................................................

04GENERAL SPECIFICATION DATA
12
INFORMATION SHOCK ABSORBERS
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
BRAKES
Front service brake
Type Outboard discs with four piston calipers.................................................................................
Operation Hydraulic, servo assisted self-adjusting.........................................................................
Pad material non asbestos.....................................................................
Rear service brake
Type Outboard discs with two piston calipers.................................................................................
Operation Hydraulic, servo assisted, self-adjusting.........................................................................
Pad material non asbestos.....................................................................
Parking brake
Type Mechanical-cable operated drum brake on the rear of.................................................................................
the transfer gearbox output shaft
Lining material non asbestos..................................................................
Servo/master cylinder non ABS
Manufacturer Lucas....................................................................
Servo type LSC 115........................................................................
Master cylinder type AS/AS.........................................................
Anti-lock brake system
Manufacturer/type Wabco 4 wheel sensed add on anti-lock brake............................................................
system.
Servo/master cylinder ABS
Manufacturer Lucas....................................................................
Master cylinder type CV/CV.........................................................