transfer case LAND ROVER DISCOVERY 2002 Workshop Manual

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.

TRANSFER BOX - LT230SE
41-28 REPAIRS
11.Remove 2 cable ties securing cable to fuel
pipes.
12.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
13.Remove banjo bolt securing breather pipe and
discard washers.
14. If fitted - Disconnect 2 Lucars from differential
lock switch.
15.Release and disconnect transfer box neutral
switch multiplug. 16.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
17.Position gearbox support jack and secure
support plate to jack using 4 bolts.
18.Remove 3 bolts securing transfer box to
gearbox.
19.Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
20.Remove 2 bolts and nut securing transfer box
to gearbox case. If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
21.Position a jack to support gearbox and engine.

TRANSFER BOX - LT230SE
OVERHAUL 41-53
11.Using feeler gauges, determine clearance
between low range gear and high/low hub:
lClearance = 0.05 to 0.15 mm (0.002 to
0.006 in).
12.If clearance is not as specified, fit a new low
range gear and high/low hub and re-check.
13.Using feeler gauges, determine clearance
between high range gear and high/low hub:
lClearance = 0.05 to 0.15 mm (0.002 to
0.006 in).
14.If clearance is not as specified, fit new high
range gear and high/low hub and re-check. 15.Using a suitable drift, stake collar of nut into
differential shaft recess.
16.Using LRT-51-009, fit new rear bearing track
into main casing.
17.Using a straight edge and feeler gauges, check
that bearing track is recessed 1 mm (0.04 in)
below outer face of main casing.
18.Apply sealant, Part No. STC 3254 to rear
output shaft housing face.
19.Position housing to main casing.
20.Apply Loctite 290 to bolt threads fit housing to
main case bolts and tighten by diagonal
selection to 45 Nm (33 lbf.ft).
21.03 MY only: Fit high/low selector fork and
spring to high/low selector shaft, fit retaining
clips.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
22.Position high/low selector shaft and fork to
differential ensuring that fingers of selector fork
are located in selector sleeve.
23.Position differential assembly into main casing
ensuring that splines of rear output shaft are
engaged in differential.
24.Position new differential front bearing track
ensuring that track is seated squarely.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-42 REPAIRS
Gasket - rear extension housing.
$% 44.20.19
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove 9 bolts securing rear extension
housing to gearbox case and remove housing.
4.Remove and discard gasket. Reassembly
1.Clean rear extension and mating face.
2.Position new gasket to gearbox case.
3.Position rear extension housing and tighten
bolts to 25 Nm (18 lbf.ft).
4.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
5.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-43
Parking pawl assembly.
$% 44.28.07
Remove
1.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
2.Remove transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
3.Remove and discard 9 bolts securing extension
housing to gearbox case.
4.Remove extension housing and discard gasket. 5.Remove Torx screw and discard, lift off parking
pawl guide and guide plate.
6.Remove ratchet, spring and pivot pin.
7. Td5 models: Remove spacer from output
shaft.
8.Remove park lock gear.
9.Remove and discard 'O' ring from output shaft.
Refit
1.Clean park lock components.
2.Lubricate and fit new 'O' ring to output shaft.
3.Position park lock gear on the output shaft.
4. Td5 models: Fit the spacer.
CAUTION: Ensure that spacer is fitted on
output shaft - Tdi Models only. If spacer is
omitted, park gear and speed sensor may
move out of position.
5.Position pivot pin, spring and ratchet.
6.Position parking pawl guide and guide plate,
tighten Torx screw to 10 Nm (8 lbf.ft).
M44 1109B
97
8

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-44 REPAIRS
7.Clean extension housing and gearbox case.
8.Position new gasket to gearbox case.
9.Position extension housing and tighten bolts to
25 Nm (18 lbf.ft).
10.Fit transfer gearbox.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - Diesel.

+ TRANSFER BOX - LT230SE,
REPAIRS, Transfer box - V8.
11.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
Gasket - oil sump
$% 44.24.05
Remove
1.Raise vehicle on ramp.
2.Drain automatic gearbox oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
3.Remove 6 bolts and spacers securing oil sump
to gearbox, remove sump and discard gasket.
Refit
1.Clean oil sump and mating face.
2.Fit new gasket to oil sump, position sump to
gearbox.
3.Position spacers and tighten bolts to 8 Nm (6
lbf. ft).
4.Fill automatic gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Automatic gearbox.
5.Lower vehicle.