Discovery 2. Manual — part 116
MANUAL GEARBOX - R380
REPAIRS
37-21
Seal - input shaft
$% 37.23.06
Remove
1. Remove gearbox assembly.
2. Remove retaining peg and remove release
bearing.
3. Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
4. Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve.
5. Remove 6 bolts securing bell housing and
remove bell housing.
6. Remove and discard 6 bolts securing oil seal
housing and remove housing.
7. Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8. Remove oil seal from housing.
MANUAL GEARBOX - R380
37-22
REPAIRS
Refit
1. Using a suitable solvent 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.
6. Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7. Clean bell housing mating faces, dowels and
dowel holes.
8. Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9. Clean release bearing sleeve mating faces,
dowel and dowel holes.
10. Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11. Examine clutch release fork pivot points for
wear and replace as required.
12. Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13. Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14. Clean release bearing and bearing sleeve
mating faces.
15. Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16. Fit release bearing and secure with retaining
peg.
17. Fit gearbox assembly.
MANUAL GEARBOX - R380
REPAIRS
37-23
Cooler - oil - gearbox - Diesel
$% 37.24.02
Remove
1. Remove intercooler.
2. Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3. Push against coupling release ring and
disconnect both fluid hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4. Remove screw securing oil cooler to radiator.
5. Release oil cooler from location on radiator,
and remove the oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1. Fit oil cooler to radiator and secure with screw.
2. Ensure connections are clean and secure
hoses to cooler.
3. Fit intercooler.
4. Top up gearbox oil level.
MANUAL GEARBOX - R380
37-24
REPAIRS
Cooler - oil - gearbox - V8
$% 37.24.02
Remove
1. If fitted: Remove engine oil cooler.
ENGINE - V8, REPAIRS, Cooler -
2. Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3. Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4. Remove screw securing oil cooler to radiator.
5. Release oil cooler from its location on radiator.
6. Move radiator towards engine sufficiently only
to release gearbox oil cooler from radiator.
7. Remove gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1. Fit gearbox oil cooler to radiator, engage in
location and secure with screw.
2. Ensure connections are clean and secure
hoses to cooler.
3. If fitted: Fit engine oil cooler.
ENGINE - V8, REPAIRS, Cooler -
4. Top up gearbox oil.
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