LAND ROVER DISCOVERY 2002 Workshop Manual

MANUAL GEARBOX - R380
37-38 OVERHAUL
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.
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.

MANUAL GEARBOX - R380
OVERHAUL 37-39
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.
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.

MANUAL GEARBOX - R380
37-40 OVERHAUL
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 Loctite 290 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.
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.

MANUAL GEARBOX - R380
OVERHAUL 37-41
5.Remove retaining ring and split collars
securing 5th gear to output shaft.
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
37-42 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.