LAND ROVER DISCOVERY 1999 Workshop Manual

MANUAL GEARBOX - R380
37-20 REPAIRS
Seal - gearbox mainshaft
$% 37.23.01
Remove
1.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
2.Using tool LRT-37-009, LRT-37–010 and
LRT-37-001/2, remove oil seal collar.
3.Remove main shaft oil seal. Refit
1.Clean oil seal recess.
2.Lubricate new seal.
3.Using tool LRT-37-014, fit new seal.
4.Clean oil seal collar and mating face.
5.Using tool LRT-37-015 and LRT-37-021, fit oil
seal collar.
6.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.

MANUAL GEARBOX - R380
REPAIRS 37-21
Seal - input shaft
$% 37.23.06
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
4.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 5.Remove 6 bolts securing bell housing and
remove bell housing.
6.Remove and discard 6 bolts securing oil seal
housing and remove housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing.

MANUAL GEARBOX - R380
37-22 REPAIRS
Refit
1.Using a suitable solvent clean seal housing
mating faces.
2.Clean seal recess, bearings and bearing races.
3.Lubricate new oil seal and fit using a suitable
mandrel into housing.
4.Fit input shaft front bearing track using a press
and suitable mandrel.
5.Apply sealant, Part No. STC 4404 to seal
housing.
6.Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7.Clean bell housing mating faces, dowels and
dowel holes.
8.Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9.Clean release bearing sleeve mating faces,
dowel and dowel holes.
10.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11.Examine clutch release fork pivot points for
wear and replace as required.
12.Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13.Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14.Clean release bearing and bearing sleeve
mating faces.
15.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16.Fit release bearing and secure with retaining
peg.
17.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.

MANUAL GEARBOX - R380
REPAIRS 37-23
Cooler - oil - gearbox - Diesel
$% 37.24.02
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release ring and
disconnect both fluid hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.
5.Release oil cooler from location on radiator,
and remove the oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.Refit
1.Fit oil cooler to radiator and secure with screw.
2.Ensure connections are clean and secure
hoses to cooler.
3.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
4.Top up gearbox oil level.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.

MANUAL GEARBOX - R380
37-24 REPAIRS
Cooler - oil - gearbox - V8
$% 37.24.02
Remove
1. If fitted: Remove engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.
5.Release oil cooler from its location on radiator. 6.Move radiator towards engine sufficiently only
to release gearbox oil cooler from radiator.
7.Remove gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Fit gearbox oil cooler to radiator, engage in
location and secure with screw.
2.Ensure connections are clean and secure
hoses to cooler.
3. If fitted: Fit engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
4.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.

MANUAL GEARBOX - R380
REPAIRS 37-25
Switch - Reverse light
$% 37.27.01
Remove
1.Raise vehicle on ramp.
2.Disconnect reverse lamp switch multiplug.
3.Remove switch and collect sealing washer.
Refit
1.Clean switch and mating face on gearbox.
2.Using a new sealing washer, fit the reverse light
switch and tighten to 24 Nm (17 lbf.ft).
3.Connect switch multiplug.
4.Lower vehicle.

MANUAL GEARBOX - R380
OVERHAUL 37-27
OVERHAUL
Shaft - output
$% 37.20.25
Disassembly
1.Remove gearbox selector fork - set

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
2.Remove gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.
3.Remove and discard oil seal and bearing tracks
from front cover.
4.Remove and discard bearing tracks from centre
plate, collect selective shims. 5.Using tool LRT-99-002 and support bars under
1st gear, press output shaft bearing from output
shaft.
6.Remove 1st gear, bearing collar, needle roller
bearing and synchromesh rings.
7.Noting its fitted position, remove 1st / 2nd gear
synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.

MANUAL GEARBOX - R380
37-28 OVERHAUL
8.Using tool LRT-99-002 and support bars under
3rd gear and press off output shaft pilot
bearing.
9.Remove spacer, 3rd / 4th gear synchroniser
hub, synchromesh baulk rings, 3rd gear and
needle roller bearing.
10.Remove output shaft. 11.Using tool LRT-37-043 and LRT-99-002,
remove taper roller bearing from input shaft.
12.Using tool LRT-37-044 and LRT-99-002,
remove bearing from splined end of layshaft.

MANUAL GEARBOX - R380
OVERHAUL 37-29
13.Using tool LRT-37-022 and LRT-99-002,
remove bearing from 4th gear end of layshaft.
Reassembly
1.Clean layshaft, input shaft and output shaft
bearing surfaces.
2.Using tool LRT-37-022, LRT-37-044 and
LRT-99-002, press new bearing onto splined
end of layshaft. 3.Using tool LRT-37-022 and LRT-99-002,
press new bearing onto 4th gear end of
layshaft.