gearbox LAND ROVER DISCOVERY 2002 Workshop Manual

MANUAL GEARBOX - R380
37-42 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 37-43
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
37-44 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 37-45
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.
Reassembly
1.Clean centre plate and reverse gear
components.
2.Lubricate gearbox components with clean gear
oil.
3.Position idler gear, bearing and spacer to idler
shaft.
4.Using a suitable press fit idler shaft to centre
plate.
5.Using feeler gauges, check clearance between
reverse idler and shaft flange; fit a thicker or
thinner spacer if necessary in order to achieve
correct clearance:
lNew clearance = 0.04 - 0.38 mm (0.002 -
0.015 in)
lService limit = 0.38 mm (0.015 in)
6.Apply sealant, Part No. STC 3254 to gearbox
casing.
7.Fit lower spring and detent ball into centre
plate, retain using a dummy shaft.
8.Align selector shaft pin with slot in centre plate.
9.Fit centre plate and fit 2 off 8x35 mm slave bolts
to retain centre plate in position on gearbox
case; recover dummy shaft.

MANUAL GEARBOX - R380
37-46 OVERHAUL
10.Fit filter to gearbox case.
11.Fit interlock spool to selector shaft.
12.Using new 'O' ring, fit spool retainer and tighten
bolts to 8 Nm (6 lbf.ft).
13.Clean threads of detent plug.
14.Apply Loctite 290 to threads of detent plug, fit
upper detent ball and spring.
15.Fit detent plug and tighten to 25 Nm (18 lbf.ft).
16.Position reverse gear to layshaft.
17.Position reverse gear complete with bearing,
collar and selective spacer to output shaft.
18.Fit 5th / reverse gear synchroniser.

+ MANUAL GEARBOX - R380,
OVERHAUL, Synchronizer assembly - 5th/
reverse.
Housing - gear selector mechanism
$% 37.16.37.01
Disassembly
1.Remove 4 bolts and remove gear selector
housing.
Reassembly
1.Clean mating faces on selector housing and
gearbox.
2.Apply sealant, STC 3254, to selector housing.
3.Clean selector housing bolt threads.
4.Apply Loctite 290 to threads of selector housing
bolts, position selector housing and tighten
bolts to 25 Nm (18 lbf.ft)
5.Adjust gear lever bias springs.

+ MANUAL GEARBOX - R380,
ADJUSTMENTS, Spring - gear lever bias.

MANUAL GEARBOX - R380
OVERHAUL 37-47
Lever - gear change
$% 37.16.04
Disassembly
1.Remove gear selector housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
2.Restrain right hand bias spring using a suitable
pair of grips.
3.Remove 2 bolts securing right hand side of bias
spring adjustment plate.
4.Repeat operations for left hand bias spring.
5.Remove bias springs and adjustment plate.6.Remove lower gear lever.
7.Remove and discard Railko bush.
8.Remove and discard oil seal from housing.
Reassembly
1.Clean components.
2.Apply multi-purpose grease to ball and cross
pins.
3.Apply multi-purpose to new Railko bush and fit
to housing ensuring that slots are correctly
aligned.
4.Lubricate a new seal with gearbox oil and fit, lip
side towards housing using a suitable mandrel.
5.Position lower gear lever to selector housing
ensuring cross pins are located in Railko bush.
6.Position bias spring adjustment plate to
selector housing.
7.Clean threads of bias spring adjustment plate
bolts and apply Loctite 290 to threads.
8.Fit 2 short bolts to secure front of adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9.Position right hand bias spring to pillar ensuring
longest end of spring is against gear lever.
10.Restrain bias spring using a suitable pair of
grips, ensure shortest end of spring is on
outside edge of bolt hole.

MANUAL GEARBOX - R380
37-48 OVERHAUL
11.Fit longest bolt and washer ensuring end of
bias spring is under washer, tighten bolt to 25
Nm (18 lbf.ft).
12.Repeat above procedures for remaining bias
spring.
13.Fit gear selector housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
14.Adjust gear lever bias springs.

+ MANUAL GEARBOX - R380,
ADJUSTMENTS, Spring - gear lever bias.
Housing - clutch
$% 37.12.07
Disassembly
1.Remove clutch release bearing and operating
lever.
2.Remove 6 bolts and remove clutch housing.
Reassembly
1.Clean clutch housing and gearbox mating face.
2.Position clutch housing and tighten bolts to 75
Nm (55 lbf.ft).
3.Fit clutch operating lever and release bearing.

MANUAL GEARBOX - R380
OVERHAUL 37-49
Cover - front
$% 37.12.33.01
Disassembly
1.Remove retaining peg and remove release
bearing.
2.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
3.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 4.Remove 6 bolts securing clutch housing and
remove clutch housing.
5.Remove and discard 6 bolts securing oil seal
housing.
6.Remove oil seal housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing, discard seal.

MANUAL GEARBOX - R380
37-50 OVERHAUL
Reassembly
1.Using a suitable solvent cleaner, 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, fit new bolts and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
6.Clean clutch housing mating faces, dowels and
dowel holes.
7.Position clutch housing, fit bolts and tighten to
75 Nm (55 lbf.ft).
8.Clean release bearing sleeve mating faces,
dowel and dowel holes.
9.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
10.Examine clutch release fork pivot points for
wear and replace as required.
11.Apply a smear of Molybdenum disulphide
grease to pivot points and position release fork.
12.Fit retaining clip ensuring it locates over pivot
point washer, fit bolt to release fork and tighten
to 10 Nm (7 lbf.ft).
13.Clean release bearing and bearing sleeve
mating faces.
14.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
15.Fit release bearing and secure with retaining
peg.

TRANSFER BOX - LT230SE
41-4 DESCRIPTION AND OPERATION
Main casing components – Vehicles up
to 03 model year
1Retaining plate
2Stake nut - intermediate shaft
3Bolt - retaining plate
4'O' rings - intermediate shaft
5Bearings and outer tracks - mainshaft input
gear
6Mainshaft input gear bearing housing
7Cover plate
8Bolt - cover plate
9Selective shim
10Mainshaft input gear
11Oil filler/level plug
12Oil temperature switch - if fitted
13Bearings and outer tracks - intermediate gears
14Circlips
15Intermediate gears
16Bottom cover plate
17Bolt - bottom cover plate
18Selective spacer
19Mainshaft oil seal20Oil drain plug
21Main casing
22Intermediate shaft
23Locating dowel
24Detent ball - high/low selector
25Detent spring - high/low selector
26Detent plug - high/low selector
27Neutral warning switch - Automatic gearbox
only - North America and Japan
28Bolt - interlock solenoid cover - Automatic
gearbox only - North America and Japan
29Cover - interlock solenoid - Automatic gearbox
only - North America and Japan
30Belleville washer - Automatic gearbox only -
North America and Japan
31Interlock solenoid - Automatic gearbox only -
North America and Japan