Discovery 2. Manual — part 28
MAINTENANCE
PROCEDURES
10-17
Manual gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1. Release fixings, remove rear underbelly panel.
2. Clean area around oil filler/level plug.
3. Remove oil filler/level plug.
4. Check that oil level is to bottom of oil filler/level
plug hole.
5. Top-up level (if required) with recommended oil
to bottom of filler/level plug hole.
LUBRICANTS AND SEALANTS,
Lubrication.
6. Remove all traces of sealant from threads of oil
filler/level plug.
7. Apply Loctite 290 to threads of oil filler/level
plug.
8. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
9. Remove all traces of oil from gearcase.
10. Fit rear underbelly panel, secure fixings.
Replace oil
1. Release fixings, remove rear underbelly panel.
2. Place a suitable container beneath gearbox
drain plug.
3. Clean area around oil filler/level and drain
plugs.
4. Remove oil filler/level plug.
5. Remove oil drain plug, remove and discard
sealing washer.
6. Allow oil to drain.
7. Clean magnet in oil drain plug.
8. Fit new sealing washer to oil drain plug.
9. Fit manual gearbox drain plug and tighten to 50
Nm (37 lbf.ft).
10. Fill gearbox with recommended oil to bottom of
filler/level plug hole.
LUBRICANTS AND SEALANTS,
Lubrication.
11. Remove all traces of sealant from threads of oil
filler/level plug.
12. Apply Loctite 290 to threads of oil filler/level
plug.
13. Fit manual gearbox filler/level plug and tighten
to 30 Nm (22 lbf.ft).
14. Remove all traces of oil from gearcase.
15. Fit rear underbelly panel, secure fixings.
MAINTENANCE
10-18
PROCEDURES
Automatic gearbox
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil filter
1. Replace oil filter.
Replace oil
1. Ensure that gearbox is cool. Apply
handbrake and securely chock front and rear
wheels.
2. Place a suitable container beneath gearbox.
3. Clean area around oil filler/level and drain
plugs.
4. Remove oil drain plug, remove and discard
sealing washer.
5. Allow oil to drain.
6. Fit new sealing washer to oil drain plug.
7. Fit automatic gearbox drain plug and tighten to
15 Nm (11 lbf.ft).
8. Remove oil filler/level plug, remove and discard
sealing washer.
9. Fill gearbox with recommended oil to bottom of
oil level/filler plug hole.
LUBRICANTS AND SEALANTS,
Lubrication.
10. Select 'P' (Park).
11. Ensure handbrake is applied.
12. Start engine and allow it to idle.
13. Apply footbrake.
14. Move selector lever through all gear positions,
while continuing to fill the gearbox. Select 'P'
(Park).
15. With engine idling, continue filling gearbox until
a 2 mm bead of oil runs from oil filler/level plug
hole.
16. Fit new sealing washer to automatic gearbox
filler/level plug, fit plug and tighten to 30 Nm (22
lbf.ft).
17. Stop engine.
18. Remove all traces of oil from gearbox casing.
MAINTENANCE
PROCEDURES
10-19
Transfer box
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Check/top-up oil level
1. Release fixings, remove rear underbelly panel.
2. Clean area around oil filler/level plug.
3. Remove oil filler/level plug.
4. Check that oil level is to bottom of filler/level
plug hole.
5. Top-up level (if required) with recommended oil
to bottom of oil filler/level plug hole.
LUBRICANTS AND SEALANTS,
Lubrication.
6. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
7. Remove all traces of oil from main casing.
8. Fit rear underbelly panel (if fitted), secure
fixings.
Replace oil
1. Release fixings, remove rear underbelly panel.
2. Place a suitable container beneath transfer box
drain plug.
3. Clean area around oil filler/level and drain
plugs.
4. Remove oil filler/level plug.
5. Remove oil drain plug.
6. Allow oil to drain.
7. Fit transfer box drain plug and tighten to 30
Nm (22 lbf.ft).
8. Fill transfer box with recommended oil to
bottom of oil filler/level plug hole.
LUBRICANTS AND SEALANTS,
Lubrication.
9. Fit transfer box filler/level plug and tighten to 25
Nm (18 lbf.ft).
10. Remove all traces of oil from transfer box.
11. Fit rear underbelly panel (if fitted), secure
fixings.
MAINTENANCE
10-20
PROCEDURES
Front and rear axle
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Replace oil
1. Place a suitable container beneath differential
housing of axle to be drained.
2. Clean area around oil filler/level and drain
plugs.
3. Remove oil filler/level plug.
4. Remove and discard 'O' ring from oil filler/level
plug.
5. Remove oil drain plug, allow oil to drain.
6. Fit axle drain plug and tighten to 64 Nm (47
lbf.ft).
7. Fill differential housing with recommended oil to
bottom of oil filler/level plug hole.
LUBRICANTS AND SEALANTS,
Lubrication.
8. Lubricate a new 'O' ring with recommended oil
and fit to oil filler/level plug.
9. Fit axle filler/level plug and tighten to 10 Nm (7
lbf.ft).
10. Remove all traces of oil from differential
housing.
Propeller shafts
Lubricate
Rear shaft
1. Clean area around front universal joint grease
nipple.
2. Apply recommended grease to the grease
LUBRICANTS AND SEALANTS,
Lubrication.
Front shaft
3. Remove blanking plug adjacent to sliding joint
from propeller shaft.
4. Screw a 1/4in UNF grease nipple into blanking
plug hole.
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