lock LAND ROVER DISCOVERY 1995 Workshop Manual

30MANIFOLD AND EXHAUST SYSTEM
8
REPAIR 6.Disconnect oxygen sensor multiplug.
7.Release multiplug from bracket on thermostat
housing.
8.Release harness from cable tie.
9.Remove drive belt.
10.Remove 2 front bolts securing generator to
mounting bracket.
11.Remove 2 rear bolts securing generator to
mounting bracket.
12.Move generator from mounting bracket and
place aside.
13.Remove exhaust manifold heat shield.
14.Remove dipstick and bolt securing dipstick tube
to coolant rail.
15.Remove dipstick tube from cylinder block.16.Remove 3 bolts and 2 nuts securing exhaust
manifold to cylinder head.
17.Release coolant rail bracket from manifold studs.
18.Remove exhaust manifold and discard gasket.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
19.Clean mating faces of exhaust manifold and
cylinder head.
20.Fit new manifold gasket and align exhaust
manifold to cylinder head.
21.Position coolant rail bracket to manifold studs.
22.Fit manifold nuts and bolts, tighten to the correct
torque in the order shown.
23.Secure oxygen sensor multiplug to bracket.
24.Connect oxygen sensor multiplug.
25.Fit new manifold flange gasket and align exhaust
front pipe to manifold.
26.Fit nuts and tighten diagonally to the correct
torque.
27.Tighten exhaust downpipe to silencer box nuts
to the correct torque.
28.Position generator to mounting bracket.
29.Fit and tighten 4 generator securing bolts.
30.Refit drive belt.

R380
1
DESCRIPTION AND OPERATION MANUAL TRANSMISSION
Description
The all synchromesh five speed manual gearbox unit,
is married to a LT230T two speed transfer gearbox.
All the gears including reverse run on needle roller
bearings and the main, layshaft and primary shafts
are supported by tapered roller bearings.The whole of the geartrain is lubricated through
drillings in the shafts, supplied by a low pressure
pump driven from the rear of the layshaft. The gear
change has a single rail selector and spool type
interlock. The main and transfer gearboxes ventilate
through nylon pipes, which terminate high up in the
engine compartment to prevent water entry when the
vehicle is operating in adverse conditions.
1. Mainshaft 1st gear
2. Mainshaft 2nd gear
3. Mainshaft 3rd gear
4. Primary input shaft
5. Mainshaft 5th gear
6. Layshaft
7. Mainshaft
8. Lubrication pump9. Drain plug
10. Ventilation pipe
11. Single rail gear shift
12. 1st/2nd synchromesh
13. Oil seals
14. 3rd/4th synchromesh
15. 5th gear synchromesh

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.

37MANUAL GEARBOX
2
REPAIR 25.Remove nuts and bolts securing transmission
cross-member to chassis.
26.Remove nuts and bolts securing cross-member
mountings to transmission.
27.Remove cross-member.
28.Manufacture an adapter plate to dimensions
given in service tool section and attach it to a
transmission hoist. To achieve balance of the
transmission unit when mounted to hoist, it is
essential that pointA,is situated over lifting hoist
ram. Drill holesBto suit hoist table. Secure the
transmission unit cradle at pointCusing the
lower bolts retaining transfer gearbox rear cover.
Raise hoist just enough to take weight of
transmission.
29.Lower hoist sufficiently to allow transfer gearbox
selector lever to clear transmission tunnel
aperture.
30.Disconnect differential lock switch connectors.
31.Disconnect reverse lamp switch connectors.
32.Remove clips securing gearbox breather pipes
to harness.
33.Support engine under sump with a jack.
CAUTION: Use a wooden block to protect
sump.
34.Remove bell housing nuts.
35.Withdraw transmission whilst ensuring all
connections to engine and chassis are released.36.Remove transmission assembly from hoist
cradle and position safely on a bench.
37.Remove breather pipes. Discard pipe union
sealing washers.
38.Remove 'Nyloc' nut, and remove bolt, securing
lever to high/low shaft.
39.Collect spacer washer.
40.Remove 2 clips and remove differential lock
lever link.
41.Remove lower locknut from high/low operating
rod.
42.Place a sling round transfer box and attach to
hoist.
43.Remove nut and 5 bolts securing transfer
gearbox to extension housing.
44.Withdraw transfer gearbox.

R380
3
REPAIR Assembling transfer gearbox to main gearbox
45.Clean extension housing and transfer gearbox
mating faces.
46.Ensuring loose upper dowel is fitted, hoist
transfer gearbox into position.
47.Fit and tighten nut and bolts to
34Nm.
48.Connect high/low operating rod, fit and tighten
locknut.
49.Fit link to differential lock lever and secure with 2
clips
50.Align lever to high/low shaft, position washer, fit
bolt and new Nyloc nut. Tighten to
2Nm.
51.Position breather pipes, secure pipe unions
using new sealing washers. Tighten unions to
15Nm.
Fitting transfer gearbox and main gearbox
assembly to engine
52.Position transmission assembly to hoist cradle.
53.Clean bell housing and engine mating faces.
54.Temporarily fit gear lever and select any gear in
main gearbox to facilitate entry of gearbox input
shaft.
55.Position and raise hoist, and fit transmission to
engine whilst keeping wires and pipes clear to
prevent trapping.
56.Fit and tighten nuts securing transmission to
engine.
57.Connect reverse lamp switch connectors and
differential lock switch connectors.
58.Secure breather pipes to harness with clips.
59.Position temporary support.
60.Remove 2 bolts securing lifting cradle to
transmission and remove hoist. Apply Loctite
290 to bolts and refit bolts.
61.Position cross-member, loosely fit nuts and bolts
securing cross-member mountings to
transmission.62.Raise transmission, align cross-member and
loosely fit nuts and bolts securing cross-member
to chassis.
63.Tighten all securing nuts and bolts. Remove
supporting jack from under sump.
64.Remove temporary support.
65.Fit handbrake cable through transmission tunnel
and secure gaiter.
66.Connect speedometer cable to transfer gearbox.
67.Line up marks and connect front and rear
propeller shafts.
68.Clean spacer, clutch slave cylinder and gearbox
mating faces.
69.Position spacer and slave cylinder, fit bolts.
Tighten to
25Nm.
70.Untie intermediate exhaust pipe(s) and refit
exhaust front pipe(s).
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust System
Complete
71.Refill main gearbox and transfer gearbox with oil.
See SECTION 10, Maintenance, Under
Vehicle Maintenance
72.Lower ramp [hoist].
73.Fit fan cowl, fit and tighten bolts.
74.Align breather pipe clip to cylinder block, fit and
tighten bolts.
75.Fit handbrake cable adjuster and secure with 'C'
clip.
76.Align cable trunnion to handbrake lever, fit clevis
pin and secure with clip.
77.Check handbrake adjustment.
See SECTION
10, Maintenance, Vehicle Interior
78.Fit upper gear lever, fit and tighten bolt.
79.Fit gear selector lever and high/low selector
lever draft excluders.
80.Position draft excluder clamp rings, fit and
tighten screws.
81.Refit sound insulation.
82.Refit centre console.
See CHASSIS AND
BODY, Repair, Centre Console
83.Connect battery earth lead.

R380
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
Slave cylinder to bell housing 25....................................................................
Breather 15.....................................................................................................
Bell housing to cylinder block 40.....................................................................
High/low level to shaft 2.................................................................................
Transfer box to gearbox 45.............................................................................
NOTE: Torque values below apply to all screws and bolts used unless otherwise specified.
METRIC Nm
M5 6...........................................................................
M6 9...........................................................................
M8 25...........................................................................
M10 45.........................................................................
M12 90.........................................................................
M14 105.........................................................................
M16 180.........................................................................
UNC / UNF
1/4 9...........................................................................
5/16 24.........................................................................
3/8 39...........................................................................
7/16 78.........................................................................
1/2 90...........................................................................
5/8 136...........................................................................

TRANSFER GEARBOX
1
DESCRIPTION AND OPERATION LT230T TRANSFER BOX
The LT230T transfer box is a permanent 4 wheel
drive, two speed ratio reducing gearbox incorporating
high and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
A shiftlock device is fitted in some territories, it is used
as a park facility and prevents accidental gear
disengagement when the ignition is switched off. An
audible neutral alarm is also fitted. This alerts the
driver when parking to move the gear lever to the high
or low position.

TRANSFER GEARBOX
3
DESCRIPTION AND OPERATION DIFFERENTIAL AND OUTPUT DRIVE ASSEMBLY
1. Differential selector assembly
2. Front output housing
3. High-low ratio cross shaft assembly
4. High-low selector shaft and lever
5. High-low selector fork and shaft
6. High-low selector finger
7. Differential lock selector shaft
8. Differential lock selector fork
9. Differential lock spring and clips
10. Front output housing cover and housing
11. Felt washer, steel washer and flange nut
12. Front output flange
13. Mud shield
14. Oil seal
15. Bearing
16. Spacer
17. Circlip
18. Differential carrier, front half19. Differential carrier, rear half
20. Retaining ring
21. Front output shaft
22. Dog clutch, front drive lock-up
23. Selective shim
24. Bearing
25. Selective thrust washers
26. Sun and planet gears
27. Thrust washers
28. Cross shafts
29. Gear low
30. Hub and sleeve assembly
31. High output gear
32. Bush
33. Bearing
34. Bearing retaining nut
35. Differential lock switch
36. Differential lock detent ball and spring

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.