Discovery 2. Manual — part 549

MANUAL GEARBOX - R380

OVERHAUL

37-49

Cover - front

$% 37.12.33.01

Disassembly

1. Remove retaining peg and remove release

bearing.

2. Remove bolt securing clutch release fork,

remove retaining clip and remove clutch
release fork.

3. Remove 2 bolts securing release bearing

sleeve and remove bearing sleeve.

4. Remove 6 bolts securing clutch housing and

remove clutch housing.

5. Remove and discard 6 bolts securing oil seal

housing.

6. Remove oil seal housing.

7. Using a soft metal drift, carefully remove input

shaft front bearing track from housing.

8. Remove oil seal from housing, discard seal.

MANUAL GEARBOX - R380

37-50

OVERHAUL

Reassembly

1. Using a suitable solvent cleaner, clean seal

housing mating faces.

2. Clean seal recess, bearings and bearing

races.

3. Lubricate new oil seal and fit using a suitable

mandrel into housing.

4. Fit input shaft front bearing track using a press

and suitable mandrel.

5. Apply sealant, Part No. STC 4404 to seal

housing, fit new bolts and tighten by diagonal
selection to 25 Nm (18 lbf.ft).

6. Clean clutch housing mating faces, dowels and

dowel holes.

7. Position clutch housing, fit bolts and tighten to

75 Nm (55 lbf.ft).

8. Clean release bearing sleeve mating faces,

dowel and dowel holes.

9. Position release bearing sleeve, fit bolts and

tighten to 25 Nm (18 lbf.ft).

10. Examine clutch release fork pivot points for

wear and replace as required.

11. Apply a smear of Molybdenum disulphide

grease to pivot points and position release fork.

12. Fit retaining clip ensuring it locates over pivot

point washer, fit bolt to release fork and tighten
to 10 Nm (7 lbf.ft).

13. Clean release bearing and bearing sleeve

mating faces.

14. Apply smear of Molybdenum disulphide grease

to release bearing sleeve.

15. Fit release bearing and secure with retaining

peg.

TRANSFER BOX - LT230SE

DESCRIPTION AND OPERATION

41-1

TRANSFER BOX - LT230SE

DESCRIPTION AND OPERATION

LT230SE transfer box

TRANSFER BOX - LT230SE

41-2

DESCRIPTION AND OPERATION

Transfer box cross section

Up to 03 Model Year section shown