LAND ROVER DISCOVERY 2002 Workshop Manual

CLUTCH - V8
33-2-14 REPAIRS
Master cylinder
$% 33.20.01
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Release spring clip securing clutch pedal
clevis pin and remove pin from push rod and
clutch pedal.
3.Position container to catch spillage. Disconnect
hydraulic pipe from clutch master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.4.Release clip and remove connecting hose from
clutch master cylinder.
5.Remove 2 bolts securing clutch master
cylinder to pedal box and remove clutch master
cylinder.
Refit
1.Clean master cylinder and pedal box mating
faces.
2.Position clutch master cylinder to pedal box, fit
bolts and tighten to 25 Nm (18 lbf.ft).
3.Position clevis pin to push-rod and clutch pedal
and secure with spring clip.
4.Fit connecting hose to brake master cylinder
and tighten clip.
5.Position hydraulic pipe and tighten union to 18
Nm (13 lbf.ft).
6.Bleed clutch.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - V8
REPAIRS 33-2-15
Bearing and lever - clutch release
$% 33.25.12
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 lever.
Remove retaining clip and remove clutch
release lever.
Refit
1.Clean clutch release lever.
2.Examine clutch release lever pivot points for
wear.
3.Apply a smear of Molybdenum disulphide
grease to clutch release lever pivot points.
4.Fit retaining clip, ensuring it locates over clutch
release lever pivot point washer. Fit bolt and
tighten to 8 Nm (6 lbf.ft).
5.Clean release bearing and bearing sleeve
mating faces.
6.Apply a smear of Molybdenum disulphide
grease to release bearing sleeve.
7.Fit release bearing and secure with retaining
peg.
8.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Slave cylinder
$% 33.35.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Position container to catch spillage.
3.Disconnect hydraulic pipe from slave cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove 2 bolts securing slave cylinder to
gearbox housing and collect heat shield.
5.Withdraw slave cylinder from gearbox housing
and push rod.
Refit
1.Clean ends of pipes, gearbox housing and
slave cylinder mating faces.
2.Lubricate end of push rod with Molybdenum
disulphide grease.
3.Locate slave cylinder to push rod and gearbox
housing.
4.Position heatshield. Fit bolts securing slave
cylinder and tighten to 25 Nm (18 lbf.ft).
5.Connect hydraulic pipe to slave cylinder.
6.Bleed clutch system.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - V8
33-2-16 REPAIRS

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-1
MANUAL GEARBOX - R380 DESCRIPTION AND OPERAT ION
R380 gearbox

MANUAL GEARBOX - R380
37-2 DESCRIPTION AND OPERATION
Gearbox casings, gear change and oil
pump

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-3
1Front cover
2Input shaft oil seal
3Oil filler/level plug
4Sealing washer
5Oil drain plug
6Gear case
7Interlock spool retainer, bolt and 'O' ring
8Centre plate
9Locating dowels
10Selector plug, detent balls and spring
11Splash shield and retaining bolt
12Extension housing
13Gate plate and retaining bolt
14Interlock spool retainer, retaining bolt and 'O'
ring – if fitted – extension housing
15Inhibitor cam spring
16Inhibitor cam
17Reverse inhibitor shaft
18Output shaft oil seal
19Oil seal collar
20Oil pump and retaining bolt
21'O' ring
22Reverse lamp switch23Oil by-pass block - UK and European models
24Bolt - oil by-pass block
25'O' ring - oil by-pass block
26Thermostat and housing - non UK and non
European models
27'O' ring - thermostat housing
28Bolt - thermostat housing
29Oil pick-up pipe
30Oil filter
31Oil pick-up ring
32Rubber gaiter
33Cable tie
34Upper gear lever
35Clamp bolt
36Bias springs
37Bolts and washers - bias adjusting plate and
housing
38Bias adjusting plate
39Lower gear lever and ball
40Railko bush
41Oil seal
42Gear change housing

MANUAL GEARBOX - R380
37-4 DESCRIPTION AND OPERATION
Selector shaft and forks, synchromesh
assemblies and gear train

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-5
13rd/4th gear selector fork
2Interlock spool
31st/2nd gear selector fork
4Selector shaft yoke pins
5Selector shaft
6Reverse/5th gear selector fork
7Selector yoke
8Setscrew
9Input shaft front taper bearing
10Input shaft
11 4th gear synchromesh ring
12Pilot taper bearing
13Spacer
143rd/4th gear synchromesh hub and sleeve
153rd gear synchromesh rings
163rd gear
17Needle roller bearings
18Output shaft
19Roll pin
20Needle bearing
212nd gear
222nd gear synchromesh rings
232nd/1st gear synchromesh hub and sleeve
241st gear synchromesh rings
251st gear
26Needle roller bearing
27Bush
28Output shaft taper bearing 29Selective shim
30Selective washer
31Bush
32Needle roller bearing
33Reverse gear
34Reverse gear synchromesh ring
35Reverse/5th gear synchromesh hub and sleeve
36Circlip
37Needle roller bearings
385th gear synchromesh ring
395th gear
405th gear segments
415th gear segment retaining ring
42Output shaft rear support bearing
43Layshaft support bearing
44Layshaft
45Layshaft support bearing
46Selective shim
47Layshaft reverse gear
48Layshaft 5th gear
49Split collar
505th gear nut
51Layshaft rear support bearing
52Spacer
53Reverse idler gear
54Needle roller bearing
55Reverse idler shaft

MANUAL GEARBOX - R380
37-6 DESCRIPTION AND OPERATION
R380 gearbox cross section
1Input shaft
2Breather
3Input shaft 4th gear
4Selector shaft
53rd/4th selector fork
6Output shaft 3rd gear
7Output shaft 2nd gear
81st/2nd selector fork
9Output shaft 1st gear
10Selective shims - output shaft and layshaft end-
float
11Selective shim - reverse gear idler shaft end-
float
125th/reverse selector fork
13Selector yoke
14Gear change assembly15Railko bush
16Output shaft 5th gear
17Output shaft oil seal
18Output shaft
19Oil pump
205th/reverse gear synchromesh assembly
21Output shaft reverse gear
22Centre plate
23Oil filter
241st/2nd synchromesh assembly
25Layshaft
263rd/4th gear synchromesh assembly
27Input shaft oil seal

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-7
Description
General
The R380 all synchromesh gearbox has five forward speeds and reverse and is mounted in line with the engine. The
clutch bell housing is bolted to the front of the gearbox and the transfer box is mounted at the rear.
Gearbox casings
Gearbox casings consist of a front cover, gearcase, centre plate and extension housing. All casings with the exception
of the front cover are located to each other by dowels and sealed. Gearbox filler/level and drain plugs are located in
the gearcase.
Reverse lamp switch
A reverse lamp switch is inserted into the extension housing. Selection of reverse gear will close the switch allowing
current from fuse 25 to flow through the switch to illuminate the reverse lamps. The switch also provides a feed to the
BCU and the automatic interior mirror - if fitted; the mirror moving to the dimming position.
Gearchange assembly
The gearchange assembly is bolted to the top of the gearcase, the upper gear lever being attached to the lower gear
lever by means of a clamp bolt. The lower gear lever ball is housed in a Railko bush inserted in the gear change
housing, the end of the lever locating in the selector yoke which is attached to the end of the selector shaft. Bias
springs provide a positive return of the gear lever to the neutral position with selection of 1st/2nd and 5th/reverse gears
being against bias spring pressure. Spring loaded detent balls fitted in the centre plate locate in grooves in the selector
shaft to provide positive gear and neutral selection.
Lubrication
Lubrication is by an oil pump located in the extension housing and driven by the layshaft with additional lubrication
being provided by splash. The pump directs oil via a filter and internal drillings in the output shaft to lubricate the
components. On non UK and non European models, provision for oil cooling is by means of a thermostat housed in
a cover bolted to the side of the extension housing. The cover incorporates tappings for connections to an oil cooler.
On UK and European models, the thermostat and cover are replaced by an oil by-pass block.
Internal pressures produced within the gearbox are vented to atmosphere via a plastic breather pipe. The pipe is
attached to the extension housing and is routed across the top of the gearcase and secured at the open end by a clip
attached to the engine cylinder block.
Selector shaft and forks
Selector forks for 1st/2nd, 3rd/4th and 5th/reverse gears are located on a single selector shaft; the 1st/2nd and 3rd/
4th selector forks are inside the main gearcase whilst the 5th/reverse selector fork is inside the extension housing.
Each of the selector forks locates inside its corresponding synchromesh hub.
Synchromesh assemblies
Each synchromesh assembly is located on the output shaft adjacent to its corresponding gears and comprises a
synchromesh ring, hub, slippers and sleeve. The hubs and slippers are retained in the sleeves by means of spring
clips. 1st/2nd and 3rd synchromesh assemblies are fitted with double synchromesh rings whilst 4th, 5th and reverse
assemblies are fitted with single rings.