Discovery 2. Manual — part 546
MANUAL GEARBOX - R380
OVERHAUL
37-37
13. Fit oil pick-up pipe with the off-set uppermost.
14. Lubricate oil pump recess with gearbox oil.
15. Lubricate a new 'O' ring with gearbox oil and fit
to oil pump.
16. Locate oil pump in extension housing with word
'TOP' towards top of housing.
17. Align oil pump fixing screw holes and tap pump
lightly around edges until it is fully in recess.
Do not attempt to pull pump into recess
using fixing screws.
18. Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
19. Remove 2 slave bolts securing centre plate to
gearbox casing.
20. Apply sealant, Part No. STC 3254 to gearbox
casing face.
21. Position extension housing, align oil pump drive
with layshaft.
22. Clean extension housing bolt threads.
23. Apply Loctite 290 to threads of extension
housing bolts, fit bolts ensuring 2 longest bolts
are in their original positions and tighten by
diagonal selection to 25 Nm (18 lbf.ft).
24. Using new 'O' ring, fit interlock spool retainer
and tighten bolt to 8 Nm (6 lbf.ft).
25. Using tool LRT-37-015 and LRT-37-021, fit oil
seal collar.
26. Clean gear selector selector housing and
mating face.
27. Apply sealant, Part No. STC 3254 to gear
selector housing face.
28. Position gear selector housing and tighten
bolts to 25 Nm (18 lbf.ft).
Pump - gearbox oil
$% 37.12.47
Disassembly
1. Remove gearbox extension.
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.
MANUAL GEARBOX - R380
37-38
OVERHAUL
Filter - gearbox oil
$% 37.12.38
Disassembly
1. Remove gearbox extension.
OVERHAUL, Extension - gearbox rear.
2. Remove oil filter from gearbox.
Reassembly
1. Clean filter recess in gearbox.
2. Fit filter.
3. Fit gearbox extension.
OVERHAUL, Extension - gearbox rear.
Gear - 5th gear set
$% 37.20.36
Disassembly
1. Remove 5th gear - layshaft.
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.
MANUAL GEARBOX - R380
OVERHAUL
37-39
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.
OVERHAUL, 5th gear - layshaft.
Synchronizer assembly - 5th/reverse
$% 37.20.38
Disassembly
1. Remove gearbox rear extension.
OVERHAUL, Extension - gearbox rear.
2. Remove 5th gear set.
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.
MANUAL GEARBOX - R380
37-40
OVERHAUL
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 Loctite 290 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.
OVERHAUL, Gear - 5th gear set.
8. Fit gearbox rear extension.
OVERHAUL, Extension - gearbox rear.
5th gear - layshaft
$% 37.20.43
Disassembly
1. Remove gearbox extension.
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.
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