Discovery 2. Manual — part 121

MANUAL GEARBOX - R380

OVERHAUL

37-41

Pump - gearbox oil

$% 37.12.47

Disassembly

1. Remove gearbox extension.

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MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

2. Remove 3 Torx screws, remove oil pump and

discard 'O' ring.

Reassembly

1. Clean oil pump recess in extension housing,

ensure screw holes are clean and dry.

2. Lubricate oil pump recess in housing with

gearbox oil.

3. Lubricate a new 'O' ring with gearbox oil and fit

to oil pump.

4. Locate oil pump in extension housing with word

'TOP' towards top of housing.

5. Align fixing screw holes and tap pump lightly

around edges until pump is fully in housing. Do
not pull pump into housing by tightening
screws.

6. Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
7. Fit gearbox extension.

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MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

Filter - gearbox oil

$% 37.12.38

Disassembly

1. Remove gearbox extension.

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MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

2. Remove oil filter from gearbox.

Reassembly

1. Clean filter recess in gearbox.
2. Fit filter.
3. Fit gearbox extension.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380

37-42

OVERHAUL

Gear - 5th gear set

$% 37.20.36

Disassembly

1. Remove 5th gear - layshaft.

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MANUAL GEARBOX - R380,

OVERHAUL, 5th gear - layshaft.

2. Using tool LRT-37-001/2, LRT-37-009 and

LRT-37-010, remove output shaft support
bearing track.

3. Remove 5th gear and baulk ring from output

shaft.

Reassembly

1. Clean gears and shafts.
2. Position 5th gear and baulk ring to output shaft.

3. Using tool LRT-37-015 and LRT-37-021, fit

support bearing track to output shaft.

4. Fit 5th gear - layshaft.

+

MANUAL GEARBOX - R380,

OVERHAUL, 5th gear - layshaft.

MANUAL GEARBOX - R380

OVERHAUL

37-43

Synchronizer assembly - 5th/reverse

$% 37.20.38

Disassembly

1. Remove gearbox rear extension.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

2. Remove 5th gear set.

+

MANUAL GEARBOX - R380,

OVERHAUL, Gear - 5th gear set.

3. Remove split needle roller bearing from output

shaft.

4. Remove and discard Allen screw and remove

gear change yoke.

5. Remove and discard circlip securing 5th/

reverse synchronizer hub to output shaft.

6. Remove synchronizer hub and selector fork

assembly.

Reassembly

1. Clean gears, shafts, bearings and selector

fork.

2. Position selector fork to synchronizer, fit

assembly to output shaft and selector shaft. Fit
new hub retaining circlip.The fit of the circlip
is controlled by the selective washer behind
the reverse gear bearing collar on the
output shaft.

3. Adjust to give a reverse gear end-float of

0.005 - 0.055mm (0.0002 - 0.0021in).

4. Apply sealant, Part No. STC 50552 to threads

of new gear change lever yoke Allen screw.

5. Position gear change lever yoke and tighten

Allen screw to 25 Nm (18 lbf.ft).

6. Position split needle roller bearing to output

shaft.

7. Fit 5th gear set.

+

MANUAL GEARBOX - R380,

OVERHAUL, Gear - 5th gear set.

8. Fit gearbox rear extension.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380

37-44

OVERHAUL

5th gear - layshaft

$% 37.20.43

Disassembly

1. Remove gearbox extension.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

2. Using a suitable two legged puller and remove

5th gear layshaft support bearing track from
end of layshaft.

3. Release staking from 5th gear retaining nut.

4. Using tool LRT-37-023 to hold 5th gear,

remove and discard stake nut.

5. Remove retaining ring and split collars

securing 5th gear to output shaft.