Discovery 2. Manual — part 115

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.

MANUAL GEARBOX - R380

37-18

REPAIRS

22. Ensure gear lever is released from grommet

and no wires or pipes are trapped when
gearbox is lowered.

23. Remove clevis pin and 'C' washer securing low

ratio selector cable to lever and release cable
from lever housing.

24. Remove 2 cable ties securing cable to fuel

pipes.

25. Disconnect 2 Lucars from oil temperature

sensor and disconnect reverse lamp switch
multiplug.

26. Remove banjo bolts securing breather pipes

and discard sealing washers.

27. Remove bolt securing breather pipe 'P' clip and

release breather pipes.

28. If fitted: Disconnect 2 Lucars from differential

lock switch, release and disconnect transfer
box neutral sensor multiplug. Release harness
from 2 retaining clips.

29. Position container to catch oil spillage

30. Remove 2 bolts securing oil cooling pipe

housing to gearbox, release housing and
discard 'O' rings.

CAUTION: Always fit plugs to open
connections to prevent contamination.

31. Using a second jack support the weight of the

engine.

MANUAL GEARBOX - R380

REPAIRS

37-19

32. Remove 8 bolts securing gearbox to engine.
33. With assistance, remove gearbox from engine.

Refit

1. Clean gearbox to engine mating faces, dowels

and dowel holes.

2. With assistance raise gearbox on jack and

align to clutch and engine.

3. Fit bolts securing gearbox to engine and

tighten to 50 Nm (37 lbf.ft).

4. Clean oil cooling pipe housing mating faces.
5. Lubricate and fit new 'O' rings to oil cooling

pipe housing.

6. Position cooling pipe housing, fit bolts and

tighten to 25 Nm (18 lbf.ft).

7. If fitted: Secure harness in retaining clips,

connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.

8. Position breather pipes and secure 'P' clip with

bolt.

9. Using new sealing washers fit breather pipe

banjo bolts and tighten to 15 Nm (11 lbf.ft).

10. Connect oil temperature sensor Lucars and

reverse lamp switch multiplug.

11. Position low ratio selector cable to housing and

secure with 'C' washer and clevis pin.

12. Secure cable to fuel pipes with new cable ties.
13. Raise gearbox, ensuring gear change lever is

located in grommet.

14. Fit gearbox mountings and tighten bolts to 85

Nm (63 lbf.ft).

15. Fit nuts to gearbox mountings and tighten to 48

Nm (37 lbf.ft).

16. Remove 3 bolts securing support plate to

gearbox.

17. Position clutch slave cylinder and heat shield,

fit bolts and tighten to 25 Nm (18 lbf.ft).

18. Clean handbrake back plate and mating face.
19. Position handbrake back plate, fit bolts and

tighten to 75 Nm (55 lbf.ft).

20. Clean handbrake drum.
21. Fit handbrake drum and tighten retaining

screw.

22. Fit front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front..

23. Fit rear propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.

24. Clean exhaust silencer and tail pipe mating

faces.

25. Position silencer and secure on mountings,

using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).

26. Fit exhaust front pipe.

+

MANIFOLDS AND EXHAUST

SYSTEMS - Td5, REPAIRS, Pipe - front.

27. Refit starter motor.

+

CHARGING AND STARTING,

REPAIRS, Starter motor - diesel.

28. Refill gearbox with oil.

+

MAINTENANCE, PROCEDURES,

Manual gearbox.

29. Refill transfer gearbox with oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

30. Fit gear lever extension, fit clamp bolt and

tighten to 25 Nm (18 lbf.ft).

31. Fit gear lever trim and gear change knob.
32. Connect battery earth lead.
33. Fit cooling fan cowl and battery cover and

secure fixings.

MANUAL GEARBOX - R380

37-20

REPAIRS

Seal - gearbox mainshaft

$% 37.23.01

Remove

1. Remove transfer gearbox.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - V8.

2. Using tool LRT-37-009, LRT-37–010 and

LRT-37-001/2, remove oil seal collar.

3. Remove main shaft oil seal.

Refit

1. Clean oil seal recess.
2. Lubricate new seal.

3. Using tool LRT-37-014, fit new seal.
4. Clean oil seal collar and mating face.

5. Using tool LRT-37-015 and LRT-37-021, fit oil

seal collar.

6. Fit transfer gearbox.

+

TRANSFER BOX - LT230SE,

REPAIRS, Transfer box - V8.