1995 LAND ROVER DISCOVERY service

CLUTCH
1
OVERHAUL MASTER CYLINDER
Service repair no - 30.20.07
1.Remove master cylinder.
See Repair, Master
Cylinder
Disassemble
2.Pull back and remove rubber sealing boot from
pushrod.
3.Depress push-rod and extract circlip.
4.Withdraw push-rod assembly.
5.Withdraw piston assembly.
6.Withdraw retainer and spring.
7.Remove two piston seals and piston washer.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid. Dry, using a lint-free cloth.
9.Examine cylinder bore and piston, ensure they
are smooth to touch with no corrosion, score
marks or ridges. If in doubt, fit new components.
10.Fit new seals and rubber boot. These items are
all included in master cylinder overhaul kit.
11.Ensure that feed and by-pass ports are not
obstructed.
12.Ensure reservoir cap vent is clear.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt. Lubricate
cylinder bore and rubber seals with new
hydraulic fluid before assembly.
13.Fit a new piston washer and thinner of two piston
seals, lip last, over piston nose, up against
drilled piston head. Fit thicker seal into piston
groove with lip facing towards seal at opposite
end.
14.Insert spring and retainer into master cylinder
bore.
15.Insert piston and seal assembly, ensuring that
seal lips do not bend back.
16.Reverse 3 and 4, correctly locating circlip.
17.Stretch new rubber boot over push-rod, pack
with rubber grease. Fit securely into locating
groove.
18.Operate push-rod several times to ensure free
movement of internal components.
19.Fit master cylinder.

33CLUTCH
2
OVERHAUL SLAVE CYLINDER
Service repair no - 33.35.07
Overhaul
1.Remove slave cylinder.
See Repair, Slave
Cylinder
Disassemble
2.Withdraw rubber boot.
3.Withdraw push-rod.
4.Remove circlip.
5.Extract piston and seal assembly, applying low
pressure air to fluid inlet if necessary.
6.Withdraw spring.
7.Remove bleed valve.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid, and dry using lint-free cloth.
9.Examine cylinder bore and piston which must be
free from corrosion, scores and ridges.
10.Replace seal and rubber boot using appropriate
repair kit.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt.
11.Fit bleed valve. Do not overtighten.
12.Lubricate seals, piston and bore using new
hydraulic fluid.
13.Fit seal into piston groove, lip of seal towards
fluid inlet end of cylinder.
14.Enter piston assembly, spring first, into cylinder
bore. Ensure that seal lip does not fold back.
15.Secure with circlip.
16.Fill rubber boot with rubber grease.
17.Reverse removal procedure. 1 to 3.

R380
1
REPAIR R380 MANUAL GEARBOX
Service repair no - 37.20.02
Remove
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer's instructions to ensure safe and
effective use of equipment.
1.Install vehicle on a ramp [hoist].
2.Disconnect battery earth lead.
3.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
4.Remove sound insulation from top of
transmission tunnel.
5.Remove bolt and remove upper gear lever.
6.Remove screws securing gear selector lever and
high/low selector lever draft excluders.
7.Remove draft excluder clamp rings.
8.Remove handbrake cable clevis pin clip and
clevis pin.
9.Remove 'C' clip and cable adjuster.
10.Select low range to prevent gear lever fouling
tunnel when removing gearbox.
11.Remove bolt securing gearbox breather pipe clip
to cylinder block.
12.Remove bolts securing fan cowl to radiator.
13.Release fan cowl from radiator and lay over fan
blades.
14.Raise ramp [hoist].
15.Drain oil from main gearbox and transfer
gearbox.
See SECTION 10, Maintenance,
Under Vehicle Maintenance
16.Remove exhaust front pipe(s).See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
System Complete
17.Release intermediate exhaust pipe(s) from
mountings and tie aside.
18.Remove bolts securing clutch slave cylinder.
19.Release slave cylinder from clutch housing and
collect spacer.
20.Mark propeller shaft drive flange relationships for
reassembly.
21.Disconnect front and rear propeller shafts from
transfer gearbox. Tie shafts aside.
22.Remove clamp and disconnect speedometer
cable from transfer gearbox.
23.Release handbrake cable from transmission
tunnel.
24.Temporarily support transmission in a way which
enables the crossmember to be removed and a
hoist cradle to be fitted.

37MANUAL GEARBOX
2
REPAIR 25.Remove nuts and bolts securing transmission
cross-member to chassis.
26.Remove nuts and bolts securing cross-member
mountings to transmission.
27.Remove cross-member.
28.Manufacture an adapter plate to dimensions
given in service tool section and attach it to a
transmission hoist. To achieve balance of the
transmission unit when mounted to hoist, it is
essential that pointA,is situated over lifting hoist
ram. Drill holesBto suit hoist table. Secure the
transmission unit cradle at pointCusing the
lower bolts retaining transfer gearbox rear cover.
Raise hoist just enough to take weight of
transmission.
29.Lower hoist sufficiently to allow transfer gearbox
selector lever to clear transmission tunnel
aperture.
30.Disconnect differential lock switch connectors.
31.Disconnect reverse lamp switch connectors.
32.Remove clips securing gearbox breather pipes
to harness.
33.Support engine under sump with a jack.
CAUTION: Use a wooden block to protect
sump.
34.Remove bell housing nuts.
35.Withdraw transmission whilst ensuring all
connections to engine and chassis are released.36.Remove transmission assembly from hoist
cradle and position safely on a bench.
37.Remove breather pipes. Discard pipe union
sealing washers.
38.Remove 'Nyloc' nut, and remove bolt, securing
lever to high/low shaft.
39.Collect spacer washer.
40.Remove 2 clips and remove differential lock
lever link.
41.Remove lower locknut from high/low operating
rod.
42.Place a sling round transfer box and attach to
hoist.
43.Remove nut and 5 bolts securing transfer
gearbox to extension housing.
44.Withdraw transfer gearbox.

R380
1
SERVICE TOOLS ADAPTER PLATE GEARBOX
Adapter plate for removing gearbox. This can be
manufactured locally to drawing shown.
MATERIAL AND WELDING SPECIFICATION
Steel Plate BS 1449 (Grade 4 or 14)
Tube BS 4848 (Part 2)
Arc Welding BS 5135

TRANSFER GEARBOX
1
REPAIR LT230T TRANSFER GEARBOX
Service repair no - 41.10.25
Remove
Adaptor plate for removing transfer gearbox
The transfer gearbox is removed from underneath the
vehicle. Using a transmission hoist with an adaptor
plate for securing the transfer gearbox to the hoist.
The adaptor can be manufactured locally to the
drawing below.
WARNING: When using a transmission
hoist it is essential to follow the hoist
manufacturer's instructions.

41TRANSFER GEARBOX
4
REPAIR SHIFTLOCK SOLENOID/NEUTRAL SWITCH
Service repair no - 41.10.63/64
This is sited on top of the transfer gearbox. Access to
the component is gained through the transmission
tunnel aperture.
Remove
1.Disconnect battery negative lead.
2.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
3.Remove rear passenger heater air ducts.
4.Remove insulation pad.
5.Remove four screws and remove main gear
lever assembly.
6.Drill out rivets and remove tunnel blanking plate.
7.Disconnect solenoid multiplug.
8.Remove four retaining bolts and remove shiftlock
solenoid cover.
9.Remove solenoid and spring washer.
10.Clean joint sealant from mating faces.
KEY
1. Gearlever
2. Transmission tunnel aperture
3. Transfer gearbox
4. Bolt
5. Switch
6. Solenoid
7. Electrical connectionsRefit
1.Apply Hylosil or equivalent sealant to mating
faces.
2.Ensure solenoid plug lead is located in cover
recess.
3.Reverse removal procedure.
4.Fit four solenoid bolts. Tighten to
9Nm.
Neutral switch, audible alarm
1.Disconnect neutral switch electrical plug.
2.Remove neutral switch from transfer box.
Refit
3.Apply Hylomar PL32/L20 or SL500 sealant to
neutral switch.
4.Reverse removal procedure.
5.Switch - Tighten to
25Nm.

TRANSFER GEARBOX
1
SERVICE TOOLS LT230T TRANSFER GEARBOX
LRT-51-003 Drive flange wrench
18G 1205
18G 1271 Oil seal remover
18G 1271
LRT-37-014 Mainshaft rear oil seal replacer
18G 1422
LRT-99-003 Oil seal replacer handle
MS 550 or 18G 134