Discovery 2. Manual — part 117

MANUAL GEARBOX - R380

REPAIRS

37-25

Switch - Reverse light

$% 37.27.01

Remove

1. Raise vehicle on ramp.

2. Disconnect reverse lamp switch multiplug.
3. Remove switch and collect sealing washer.

Refit

1. Clean switch and mating face on gearbox.
2. Using a new sealing washer, fit the reverse light

switch and tighten to 24 Nm (17 lbf.ft).

3. Connect switch multiplug.
4. Lower vehicle.

MANUAL GEARBOX - R380

OVERHAUL

37-27

OVERHAUL

Shaft - output

$% 37.20.25

Disassembly

1. Remove gearbox selector fork - set

+

MANUAL GEARBOX - R380,

OVERHAUL, Fork - set - selector shaft.

2. Remove gearbox front cover.

+

MANUAL GEARBOX - R380,

OVERHAUL, Cover - front.

3. Remove and discard oil seal and bearing tracks

from front cover.

4. Remove and discard bearing tracks from centre

plate, collect selective shims.

5. Using tool LRT-99-002 and support bars under

1st gear, press output shaft bearing from output
shaft.

6. Remove 1st gear, bearing collar, needle roller

bearing and synchromesh rings.

7. Noting its fitted position, remove 1st / 2nd gear

synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.

MANUAL GEARBOX - R380

37-28

OVERHAUL

8. Using tool LRT-99-002 and support bars under

3rd gear and press off output shaft pilot
bearing.

9. Remove spacer, 3rd / 4th gear synchroniser

hub, synchromesh baulk rings, 3rd gear and
needle roller bearing.

10. Remove output shaft.

11. Using tool LRT-37-043 and LRT-99-002,

remove taper roller bearing from input shaft.

12. Using tool LRT-37-044 and LRT-99-002,

remove bearing from splined end of layshaft.