Discovery 2. Manual — part 12

GENERAL DATA

04-13

Manual gearbox - R380

Type

Single helical constant mesh

Gears

5 forward, 1 reverse, all synchromesh

Gear ratios: Td5 Diesel

⇒

First

3.692 : 1

⇒

Second

2.132 : 1

⇒

Third

1.397 : 1

⇒

Fourth

1.0 : 1

⇒

Fifth

0.770 : 1

⇒

Reverse

3.536 : 1

Gear ratios: V8 Petrol

⇒

First

3.321:1

⇒

Second

2.132:1

⇒

Third

1.397:1

⇒

Fourth

1.0:1

⇒

Fifth

0.732:1

⇒

Reverse

3.536:1

Baulk ring clearance:

⇒

New

0.500 mm (0.0197 in)

⇒

Service limit

0.500 mm (0.0197 in)

⇒

Selector fork pad widths - minimum

6.5 mm (0.255 in)

First gear end float:

⇒

New

0.050 - 0.200 mm (0.0020 - 0.0079 in)

⇒

Service limit

0.327 mm (0.0129 in)

Second gear end float:

⇒

New

0.040 - 0.210 mm (0.0016 - 0.0083 in)

⇒

Service limit

0.337 mm (0.0133 in)

Third gear end float:

⇒

New

0.110 - 0.210 mm (0.0043 - 0.0083 in)

⇒

Service limit

0.337 mm (0.0133 in)

Adjust fifth / reverse hub - shim to

⇒

New

0.005 - 0.055 mm (0.0002 - 0.0022 in)

⇒

Service limit

0.055 mm (0.0022 in)

Reverse gear idler shaft clearance

⇒

New

0.040 - 0.380 mm (0.0016 - 0.0150 in)

⇒

Service limit

0.380 mm (0.0150 in)

Mainshaft end float:

⇒

New

0.000 - 0.050 mm (0.0000 - 0.0020 in)

⇒

Service limit

0.000 - 0.050 mm (0.0000 - 0.0020 in)

Layshaft end float:

⇒

New

0.000 - 0.050 mm (0.0000 - 0.0020 in)

⇒

Service limit

0.000 - 0.050 mm (0.0000 - 0.0020 in)

GENERAL DATA

04-14

Transfer box - LT230SE

Type

LT230SE, two speed reduction with front and rear drives

Reduction ratios:

⇒

High range

1.211 : 1

⇒

Low range

3.32 : 1

Low range gear to high/low range hub clearance

0.05 to 0.15 mm (0.002 to 0.006 in)

High range gear to high/low range hub clearance

0.05 to 0.15 mm (0.002 to 0.006 in)

Mainshaft input gear bearing pre-load

0.05 mm (0.002 in)

Intermediate gear bearing pre-load

Torque intermediate shaft nut to 88 Nm (65 lbf.ft)

GENERAL DATA

04-15

Automatic gearbox - ZF4HP22/24

Type

ZF4HP22, electro-hydraulic shift control with fluid torque converter

Gears

4 forward, 1 reverse

Gear ratios:

⇒

First

2.480:1

⇒

Second

1.480:1

⇒

Third

1.000:1

⇒

Fourth

0.728:1

⇒

Reverse

2.086:1

Torque converter lock-up

Engaged in third and fourth gears above 72 km/h (45 mph)

Input shaft axial end-float

0.2 to 0.4 mm (0.008 to 0.016 in)

GENERAL DATA

04-16

Rear axle

Front axle

Type

Solid axle casing incorporating a spiral bevel differential and drive
shafts

Reduction ratio

3.538:1

Type

Solid axle casing incorporating spiral bevel differential and drive shafts
with constant velocity joints.

Reduction ratio

3.538:1