LAND ROVER DISCOVERY 2002 Workshop Manual

MANUAL GEARBOX - R380
37-8 DESCRIPTION AND OPERATION
The gear train
The gear train comprises an input shaft, output shaft, layshaft and reverse idler shaft together with their appropriate
gears and synchromesh assemblies.
The gear train input shaft, output shaft and layshaft are supported by taper roller bearings with all gears on the input
and output shafts running on caged needle roller bearings. Layshaft gears are integral with the shaft with the
exception of reverse/5th gears which are splined to the shaft and retained with a nut. 1st, 2nd, 3rd and 4th gears are
shot peened to improve durability. The reverse idler shaft and gear are supported in the centre plate by a caged
needle roller bearing. End-float of the output shaft and layshaft is controlled by selective shims located in the centre
plate whilst reverse idler shaft end-float is controlled by a selective shim located behind reverse gear.
Operation
Drive is transmitted from the crankshaft, through the clutch to the gearbox input shaft which transmits drive via the
layshaft to the output shaft in all gears with the exception of 4th gear which provides a direct drive from the input shaft
to the output shaft. Drive from the gearbox output shaft is transmitted to the transfer box input shaft via a flange splined
to the output shaft.

MANUAL GEARBOX - R380
ADJUSTMENTS 37-9
ADJUST ME NTS
Spring - gear lever bias
$% 37.16.26
Adjust
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
2.Loosen pinch bolt and remove gear lever
extension.
3.Drill out 9 pop rivets and remove gear lever
cover plate and seal.
4.Remove retaining strap and remove gear lever
housing rubber boot.5.Loosen bias adjustment plate bolts.
6.Select 4th gear and move lever fully to the right
and tighten bias plate adjustment bolts to 25
Nm (18 lbf.ft).
7.Check adjustment is correct by selecting 3rd
and 4th gears.
8.Fit gear lever housing rubber and secure with
retaining strap.
9.Fit seal and cover plate and secure with pop
rivets.
10.Fit gear lever extension and tighten pinch bolt
to 25 Nm (18 lbf.ft).
11.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.

MANUAL GEARBOX - R380
37-10 ADJUSTMENTS

MANUAL GEARBOX - R380
REPAIRS 37-11
REPAIRS
Housing - gear selector
$% 37.16.37
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
2.Loosen pinch bolt and remove gear lever
extension.
3.Drill out 9 pop rivets and remove gear lever
cover plate and seal.
4.Remove retaining strap and remove gear lever
housing rubber boot.5.Remove 4 bolts securing gear selector
housing.
6.Remove gear selector housing.
Refit
1.Clean mating faces on selector housing and
gearbox.
2.Apply sealant, Part No. STC 3254 to selector
housing.
3.Clean selector housing bolt threads and apply
Loctite 290 to threads.
4.Position selector housing and tighten bolts to
25 Nm (18 lbf.ft).
5.Loosen bias adjustment plate bolts.
6.Select 4th gear, move lever fully to the right
and tighten bias adjustment plate bolts to 25
Nm (18 lbf.ft)
7.Check adjustment is correct by selecting 3rd
and 4th gears.
8.Fit gear lever housing rubber and secure with
retaining strap.
9.Fit seal and cover plate and secure with pop
rivets.
10.Fit gear lever extension and tighten pinch bolt
to 25 Nm (18 lbf.ft).
11.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.

MANUAL GEARBOX - R380
37-12 REPAIRS
Gearbox - V8
$% 37.20.02.99
Remove
1.Release turnbuckles and remove battery cover
and cooling fan cowl.
2.Disconnect battery earth lead.
3.Remove gear lever knob and gear lever trim.
4.Remove clamp bolt and remove gear lever
extension. Apply lubricant to gear lever to aid
removal through grommet.
5.Remove front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
6.Drain gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.7.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
8.Remove 8 bolts securing rear cross member
and remove cross member.
9.Remove 3 nuts securing intermediate silencer
to tail pipe.
10.Release silencer from mounting rubbers,
remove silencer and discard gasket.
11.Mark front propeller shaft to transfer gearbox
and differential flanges.

MANUAL GEARBOX - R380
REPAIRS 37-13
12.Remove 8 nuts securing front propeller shaft to
transfer gearbox and differential.
13.Remove propeller shaft.
14.Repeat above operation for rear propeller
shaft.
15.Remove handbrake drum retaining screw and
remove handbrake drum.
16.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
17.Remove 2 bolts securing clutch slave cylinder,
collect heat shield, release slave cylinder and
position aside. 18.Fit support plate LRT-99-007 to gearbox jack.
19.Position gearbox jack and support plate to
gearbox and secure with 3 bolts.
20.Support the weight of gearbox, remove nuts
securing gearbox mountings to body.
21.Remove 8 bolts securing mountings to
gearbox, raise gearbox and remove both
mountings.
22.Lower gearbox sufficiently to access top of
gearbox.
23.Ensure gear lever is released from grommet
and no wires or pipes are trapped when
gearbox is lowered.

MANUAL GEARBOX - R380
37-14 REPAIRS
24.Remove clevis pin and 'C' washer securing low
ratio selector cable to lever and release cable
from lever housing.
25.Remove 2 cable ties securing cable to fuel
pipes.
26.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
27.Remove banjo bolts securing breather pipes
and discard sealing washers. 28.Remove bolt securing breather pipe 'P' clip and
release breather pipes.
29. If fitted: Disconnect 2 Lucars from differential
lock switch, release and disconnect transfer
box neutral sensor multiplug.
30. If fitted: Release harness from 2 retaining
clips.
31.Position container to catch oil spillage
32.Remove 3 bolts securing oil cooling pipe
housing to gearbox, release housing and
discard 'O' rings.
33.Using a second jack support the weight of the
engine.

MANUAL GEARBOX - R380
REPAIRS 37-15
34.Remove 14 bolts securing gearbox to engine.
35.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.Raise gear gearbox on jack and align to clutch
and engine.
3.Fit bolts securing gearbox to engine and
tighten to 45 Nm (33 lbf.ft).
4.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
5.Position coolant pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
6. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to neutral sensor.
7.Position breather pipes and secure 'P' clip with
bolt.
8.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
9.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
10.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
11.Secure cable to fuel pipes with new cable ties.
12.Raise gearbox, ensuring gear change lever is
located in grommet.
13.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft). 14.Fit nuts to mountings and tighten to 48 Nm (37
lbf.ft).
15.Remove 3 bolts securing support plate to
gearbox.
16.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
17.Clean handbrake back plate and mating face.
18.Position handbrake back plate, fit bolts and
tighten to 75 Nm (46 lbf.ft).
19.Clean handbrake drum.
20.Fit handbrake drum and tighten retaining
screw.
21.Clean propeller shafts and mating faces.
22.Position propeller shafts, align to marks and
tighten bolts to 47 Nm (35 lbf.ft).
23.Clean exhaust silencer and tail pipe mating
faces.
24.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
25.Position rear cross member, fit bolts and
tighten to 25 Nm (18 lbf.ft).
26.Refill gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
27.Refill transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
28.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
29.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
30.Fit gear lever trim and gear change knob.
31.Connect battery earth lead.
32. Fit battery cover and cooling fan cover and
secure fixings.

MANUAL GEARBOX - R380
37-16 REPAIRS
Gearbox - Diesel
$% 37.20.02.99
Remove
1.Release turn buckles and remove battery cover
and cooling fan cowl.
2.Disconnect battery earth lead.
3.Remove gear lever knob and gear lever trim.
4.Remove clamp bolt and remove gear lever
extension.
5.Apply a little lubricant to gear lever to aid
removal through grommet.
6.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.7.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
8.Drain gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove 3 nuts securing intermediate silencer
to tail pipe.
11.Release silencer from mounting rubbers,
remove silencer and discard gasket.
12.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

MANUAL GEARBOX - R380
REPAIRS 37-17
14.Remove handbrake drum retaining screw and
remove handbrake drum.
15.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
16.Remove 2 bolts securing clutch slave cylinder,
collect heat shield, release slave cylinder and
position aside.
17.Fit support plate LRT-99-007 to gearbox jack.
18.Position gearbox jack and support plate to
gearbox and secure with 3 bolts. 19.Support the weight of gearbox, remove nuts
securing gearbox mountings to body.
20.Remove 4 bolts securing both mountings to
gearbox, raise gearbox and remove both
mountings.
21.Lower gearbox sufficiently to access top of
gearbox.
22.Ensure gear lever is released from grommet
and no wires or pipes are trapped when
gearbox is lowered.