LAND ROVER DISCOVERY 2002 Workshop Manual

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
DESCRIPTION AND OPERATION 41-1
TRANSFE R BOX - LT 230SE DESCRIPTION AND OPERAT ION
LT230SE transfer box

TRANSFER BOX - LT230SE
41-2 DESCRIPTION AND OPERATION
Transfer box cross section
Up to 03 Model Year section shown

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-3
1Rear output housing
2Differential rear bearing
3High range gear and bush
4Main casing
5High/low selector sleeve and hub
6Low range gear
7Differential assembly
8Front output housing
9Differential front bearing
10Selective shim - differential bearing pre-load
11Dog clutch - Differential lock - If fitted
12Front output flange
13Differential lock selector shaft - Differential lock
- If fitted
14Selector fork - Differential lock - If fitted
15Front output shaft
16Selective spacer - intermediate gear bearing
pre-load
17Mainshaft input gear
18Selective shim - input gear bearing pre-load
19Intermediate shaft
20Intermediate gear cluster
21Rear output shaft
22Rear output flange

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

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-5
Main casing components – Vehicles
from 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 gears14Intermediate gears
15Bottom cover plate
16Bolt - bottom cover plate
17Selective spacer
18Mainshaft oil seal
19Oil drain plug
20Main casing
21Intermediate shaft
22Locating dowel
23Detent ball - high/low selector
24Detent spring - high/low selector
25Detent plug - high/low selector
26Neutral warning switch - Automatic gearbox
only - North America and Japan

TRANSFER BOX - LT230SE
41-6 DESCRIPTION AND OPERATION
Differential components – Vehicles up to
03 model year
1Retaining ring
2Differential carrier - rear half
3Low range gear
4High/low hub
5High/low selector sleeve
6High/low selector shaft
7High/low selector fork
8Setscrew - high/low selector fork
9High range gear
10High range gear bush
11Differential rear bearing
12Bearing outer track13Bearing retaining nut
14Dished thrust washers
15Planet gears
16Cross shafts
17Sun gears
18Selective thrust washers
19Differential carrier - front half
20Bolt - differential carriers
21Differential front bearings
22Bearing outer track
23Selective shim

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-7
Differential components – Vehicles from
03 model year
1Retaining ring
2Differential carrier - rear half
3Low range gear
4High/low hub
5High/low selector sleeve
6High/low selector shaft
7High/low selector fork
8Clip (2 off)
9Spring
10Setscrew - high/low selector fork
11High range gear
12High range gear bush
13Differential rear bearing14Bearing outer track
15Bearing retaining nut
16Dished thrust washers
17Planet gears
18Cross shafts
19Sun gears
20Selective thrust washers
21Differential carrier - front half
22Bolt - differential carriers
23Differential front bearings
24Bearing outer track
25Selective shim