LAND ROVER DISCOVERY 1999 Workshop Manual

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 37-41
Pump - gearbox oil
$% 37.12.47
Disassembly
1.Remove gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove 3 Torx screws, remove oil pump and
discard 'O' ring.
Reassembly
1.Clean oil pump recess in extension housing,
ensure screw holes are clean and dry.
2.Lubricate oil pump recess in housing with
gearbox oil.
3.Lubricate a new 'O' ring with gearbox oil and fit
to oil pump.
4.Locate oil pump in extension housing with word
'TOP' towards top of housing.
5.Align fixing screw holes and tap pump lightly
around edges until pump is fully in housing. Do
not pull pump into housing by tightening
screws.
6.Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
7.Fit gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
Filter - gearbox oil
$% 37.12.38
Disassembly
1.Remove gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove oil filter from gearbox.
Reassembly
1.Clean filter recess in gearbox.
2.Fit filter.
3.Fit gearbox extension.

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

MANUAL GEARBOX - R380
37-42 OVERHAUL
Gear - 5th gear set
$% 37.20.36
Disassembly
1.Remove 5th gear - layshaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, 5th gear - layshaft.
2.Using tool LRT-37-001/2, LRT-37-009 and
LRT-37-010, remove output shaft support
bearing track.
3.Remove 5th gear and baulk ring from output
shaft. Reassembly
1.Clean gears and shafts.
2.Position 5th gear and baulk ring to output shaft.
3.Using tool LRT-37-015 and LRT-37-021, fit
support bearing track to output shaft.
4.Fit 5th gear - layshaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, 5th gear - layshaft.

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
37-46 OVERHAUL
Bearing - layshaft rear support
$% 37.20.58
Disassembly
1.Remove extension housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove 3 Torx screws, remove oil pump and
discard 'O' ring.
3.Drift out layshaft support bearing.
4.Using a suitable two legged puller remove 5th
gear layshaft support bearing track from end of
layshaft. Reassembly
1.Clean layshaft and bearing recess in extension
housing.
2.Fit layshaft support bearing.
3.Clean oil pump recess in extension housing,
ensure screw holes are clean and dry.
4.Lubricate oil pump recess in housing with
gearbox oil.
5.Lubricate a new 'O' ring with gearbox oil and fit
to oil pump.
6.Locate oil pump in extension housing with word
'TOP' towards top of housing.
7.Align fixing screw holes and tap pump lightly
around edges until pump is fully in housing. Do
not pull pump into housing by tightening
screws.
8.Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
9.Apply a small amount of heat and fit support
bearing track to layshaft.
10.Fit extension housing.

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

MANUAL GEARBOX - R380
OVERHAUL 37-47
Bearing - output shaft rear support
$% 37.20.55
Disassembly
1.Remove extension housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Using tool LRT-37-001/2, LRT-37-009 and
LRT-37-010, remove output shaft support
bearing track.
3.Remove output shaft rear oil seal. 4.Remove output shaft support bearing and oil
pick-up ring.
Reassembly
1.Clean output shaft and bearing recess in
extension housing.
2.Fit output shaft support bearing and oil pick-up
ring. (Align tag with centre of drain slot).
3.Fit new output shaft oil seal using LRT-37-014.

MANUAL GEARBOX - R380
37-48 OVERHAUL
4.Using tool LRT-37-015 and LRT-37-021, fit
support bearing track to output shaft.
5.Fit extension housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
Shaft - reverse idler
$% 37.20.13
Disassembly
1.Remove 5th / reverse gear synchroniser.

+ MANUAL GEARBOX - R380,
OVERHAUL, Synchronizer assembly - 5th/
reverse.
2.Remove reverse gear complete with needle
roller bearing and collar noting selective spacer
between collar and centre plate bearing.
3.Remove layshaft reverse gear noting oil groove
faces centre plate bearing.
4.Remove detent screw from centre plate and
collect upper detent ball and spring.

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.