gearbox LAND ROVER DISCOVERY 2002 Workshop Manual

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.
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.

MANUAL GEARBOX - R380
REPAIRS 37-23
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.
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.

MANUAL GEARBOX - R380
37-24 REPAIRS
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.
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 37-25
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
37-26 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 37-27
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.
4.Using tools LRT-37-043, LRT-37-043/2 and
LRT-99-002, press new bearing onto input
shaft.
5.Using tool LRT-99-002 and a suitable mandrel,
fit input shaft outer bearing track to front cover.

MANUAL GEARBOX - R380
37-28 OVERHAUL
6.Fit layshaft bearing track to front cover.
7.Using tool LRT-99-002 and a suitable mandrel,
fit pilot bearing outer track to input shaft.
8.Clean synchroniser hubs, gears and bearings.
9.Position output shaft in protected vice jaws,
output end upwards.
10.Fit 2nd gear bearing, 2nd gear and
synchromesh baulk rings onto output shaft.
11.Position 1st / 2nd synchroniser hub onto output
shaft. Ensure that baulk rings are correctly
located in hub.
12.Position 1st gear synchromesh baulk rings,
needle roller bearing, 1st gear and bearing
collar onto output shaft. Ensure baulk rings are
correctly located in hub.
13.Remove output shaft from vice.
14.Using tool LRT-37-001, LRT-37-044 and
LRT-99-002, press taper bearing onto output
shaft.
15.Using a feeler gauge, check end float of 1st
gear between gear and collar flange:
lNew = 0.05 - 0.20 mm (0.002 - 0.008 in)
lService limit = 0.327 mm (0.012 in) 16.Using a feeler gauge, check end float of 2nd
gear between gear and output shaft flange:
lNew = = 0.04 - 0.21 mm (0.0016 - 0.0083
in)
lService limit = 0.337 mm (0.013 in)
17.Invert output shaft in vise and fit 3rd gear,
bearing, baulk rings, 3rd / 4th synchroniser and
spacer.
18.Remove output shaft from vice.
19.Using tool LRT-99-002 and a suitable mandrel,
press pilot bearing onto output shaft.

MANUAL GEARBOX - R380
OVERHAUL 37-29
20.Check end float of 3rd gear between gear and
flange on output shaft:
lNew = 0.11 - 0.21 mm (0.004 - 0.0083 in)
lService limit = 0.337 mm (0.013 in)
21.Check output shaft and layshaft end float as
follows.
22.The end float setting for both shafts is:
lNew = 0.00 to 0.05 mm (0.0 to - 0.002 in)
lService limit = 0.05 mm (0.002 in)
23.Fit front cover to gearbox case without the oil
seal and tighten bolts by diagonal selection to
25 Nm (18 lbf.ft).
24.Position in vice with front cover facing
downwards.
25.Fit input shaft to gearbox case less 4th gear
baulk ring.
26.Fit output shaft assembly to input shaft.
27.Fit output shaft bearing track and shim to centre
plate.
28.Fit centre plate to gearbox case and secure
using 8 slave bolts.
29.Rotate output shaft to settle bearings.
30.Fit a suitably large ball bearing into end of
output shaft.
31.Position a suitable DTI and zero probe on ball
bearing.
32.Lift output shaft and note DTI reading.
33.If reading is incorrect, dismantle and fit shim to
give correct end float.
34.Repeat above procedure.
35.Repeat procedure for layshaft end float.
36.Remove and discard 6 bolts and remove
gearbox front cover.
37.Fit gearbox selector fork - set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
38.Fit gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.
Synchroniser - gearbox - set
$% 37.20.07
Disassembly
1.Remove gearbox selector fork set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
2.Using tool LRT-99-002 and support bars
under 1st gear, press output shaft bearing from
output shaft.
3.Remove 1st gear, bearing collar, needle roller
bearing and synchromesh rings.
4.Noting its fitted position, remove 1st / 2nd gear
synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.

MANUAL GEARBOX - R380
37-30 OVERHAUL
5.Using tool LRT-99-002 and support bars under
3rd gear, press off output shaft pilot bearing.
6.Remove spacer, 3rd / 4th gear synchroniser
hub, synchromesh baulk rings, 3rd gear and
needle roller bearing.
7.Remove output shaft.
Reassembly
1.Clean output shaft, synchroniser hubs, gears
and bearings.
2.Position output shaft in protected vice jaws,
output end upwards.
3.Fit 2nd gear bearing, 2nd gear and
synchromesh baulk rings onto output shaft.
4.Position 1st / 2nd synchroniser hub onto output
shaft. Ensure that baulk rings are correctly
located in hub.
5.Position 1st gear synchromesh baulk rings,
needle roller bearing, 1st gear and bearing
collar onto output shaft. Ensure baulk rings are
correctly located in hub.
6.Remove output shaft from vice. 7.Using tool LRT-37-001, LRT-37-044 and
LRT-99-002, press taper bearing onto output
shaft.
8.Check end float of 1st gear using a feeler gauge
between gear and collar flange:
lNew = 0.05 - 0.20 mm (0.002 - 0.008 in)
lService limit = 0.327 mm (0.012 in)
9.Check end float of 2nd gear using a feeler
gauge between gear and output shaft flange:
lNew = 0.04 - 0.21 mm (0.0016 - 0.0083 in)
lService limit = 0.337 mm (0.013 in)

MANUAL GEARBOX - R380
OVERHAUL 37-31
10.Invert output shaft in vice and fit 3rd gear,
bearing, baulk rings, 3rd / 4th synchroniser and
spacer.
11.Remove output shaft from vice.
12.Using tool LRT-99-002 and a suitable mandrel
press pilot bearing onto output shaft.
13. Check end float of 3rd gear between gear and
flange on output shaft.
lNew = 0.11 - 0.21 mm (0.004 - 0.0083 in)
lService limit = 0.337 mm (0.013 in)
14.Fit gearbox selector fork set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
Fork - set - selector shaft
$% 37.16.45
Disassembly
1.Remove reverse idler gear shaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, Shaft - reverse idler.
2.With assistance, remove output shaft, selector
shaft and layshaft assemblies.
3.Remove selector shaft and fork assembly from
output shaft synchronisers.
4.Inspect the selector fork pads for wear, the
wear limit is 6.5 mm (2.559 in).