Discovery 2. Manual — part 540

MANUAL GEARBOX - R380

REPAIRS

37-13

12. Remove 8 nuts securing front propeller shaft to

transfer gearbox and differential.

13. Remove propeller shaft.
14. Repeat above operation for rear propeller

shaft.

15. Remove handbrake drum retaining screw and

remove handbrake drum.

16. Remove 4 bolts from handbrake back plate,

release back plate and tie aside.

17. Remove 2 bolts securing clutch slave cylinder,

collect heat shield, release slave cylinder and
position aside.

18. Fit support plate LRT-99-007 to gearbox jack.
19. Position gearbox jack and support plate to

gearbox and secure with 3 bolts.

20. Support the weight of gearbox, remove nuts

securing gearbox mountings to body.

21. Remove 8 bolts securing mountings to

gearbox, raise gearbox and remove both
mountings.

22. Lower gearbox sufficiently to access top of

gearbox.

23. Ensure gear lever is released from grommet

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

MANUAL GEARBOX - R380

37-14

REPAIRS

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

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

25. Remove 2 cable ties securing cable to fuel

pipes.

26. Disconnect 2 Lucars from oil temperature

sensor and disconnect reverse lamp switch
multiplug.

27. Remove banjo bolts securing breather pipes

and discard sealing washers.

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

release breather pipes.

29. If fitted: Disconnect 2 Lucars from differential

lock switch, release and disconnect transfer
box neutral sensor multiplug.

30. If fitted: Release harness from 2 retaining

clips.

31. Position container to catch oil spillage

32. Remove 3 bolts securing oil cooling pipe

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

33. Using a second jack support the weight of the

engine.

MANUAL GEARBOX - R380

REPAIRS

37-15

34. Remove 14 bolts securing gearbox to engine.
35. With assistance, remove gearbox from engine.

Refit

1. Clean gearbox to engine mating faces, dowels

and dowel holes.

2. Raise gear gearbox on jack and align to clutch

and engine.

3. Fit bolts securing gearbox to engine and

tighten to 45 Nm (33 lbf.ft).

4. Lubricate and fit new 'O' rings to oil cooling

pipe housing.

5. Position coolant pipe housing, fit bolts and

tighten to 25 Nm (18 lbf.ft).

6. If fitted: Secure harness in retaining clips,

connect Lucars to differential lock warning
switch and multiplug to neutral sensor.

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

bolt.

8. Using new sealing washers fit breather pipe

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

9. Connect oil temperature sensor Lucars and

reverse lamp switch multiplug.

10. Position low ratio selector cable to housing and

secure with 'C' washer and clevis pin.

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

located in grommet.

13. Fit gearbox mountings and tighten bolts to 85

Nm (63 lbf.ft).

14. Fit nuts to mountings and tighten to 48 Nm (37

lbf.ft).

15. Remove 3 bolts securing support plate to

gearbox.

16. Position clutch slave cylinder and heat shield,

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

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

tighten to 75 Nm (46 lbf.ft).

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

screw.

21. Clean propeller shafts and mating faces.
22. Position propeller shafts, align to marks and

tighten bolts to 47 Nm (35 lbf.ft).

23. Clean exhaust silencer and tail pipe mating

faces.

24. Position silencer and secure on mountings,

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

25. Position rear cross member, fit bolts and

tighten to 25 Nm (18 lbf.ft).

26. Refill gearbox with oil.

+

MAINTENANCE, PROCEDURES,

Manual gearbox.

27. Refill transfer gearbox oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

28. Fit front exhaust pipe.

+

MANIFOLDS AND EXHAUST

SYSTEMS - V8, REPAIRS, Front pipe.

29. Fit gear lever extension, fit clamp bolt and

tighten to 25 Nm (18 lbf.ft).

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

secure fixings.

MANUAL GEARBOX - R380

37-16

REPAIRS

Gearbox - Diesel

$% 37.20.02.99

Remove

1. Release turn buckles and remove battery cover

and cooling fan cowl.

2. Disconnect battery earth lead.

3. Remove gear lever knob and gear lever trim.

4. Remove clamp bolt and remove gear lever

extension.

5. Apply a little lubricant to gear lever to aid

removal through grommet.

6. Remove exhaust front pipe.

+

MANIFOLDS AND EXHAUST

SYSTEMS - Td5, REPAIRS, Pipe - front.

7. Remove starter motor.

+

CHARGING AND STARTING,

REPAIRS, Starter motor - diesel.

8. Drain gearbox oil.

+

MAINTENANCE, PROCEDURES,

Manual gearbox.

9. Drain transfer gearbox oil.

+

MAINTENANCE, PROCEDURES,

Transfer box.

10. Remove 3 nuts securing intermediate silencer

to tail pipe.

11. Release silencer from mounting rubbers,

remove silencer and discard gasket.

12. Remove front propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - front.

13. Remove rear propeller shaft.

+

PROPELLER SHAFTS, REPAIRS,

Propeller shaft - rear.