1999 LAND ROVER DISCOVERY engine oil

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-7
Description
General
The R380 all synchromesh gearbox has five forward speeds and reverse and is mounted in line with the engine. The
clutch bell housing is bolted to the front of the gearbox and the transfer box is mounted at the rear.
Gearbox casings
Gearbox casings consist of a front cover, gearcase, centre plate and extension housing. All casings with the exception
of the front cover are located to each other by dowels and sealed. Gearbox filler/level and drain plugs are located in
the gearcase.
Reverse lamp switch
A reverse lamp switch is inserted into the extension housing. Selection of reverse gear will close the switch allowing
current from fuse 25 to flow through the switch to illuminate the reverse lamps. The switch also provides a feed to the
BCU and the electrochromic automatic interior mirror - if fitted; the mirror moving from the dimmed position if
applicable.
Gearchange assembly
The gearchange assembly is bolted to the top of the gearcase, the upper gear lever being attached to the lower gear
lever by means of a clamp bolt. The lower gear lever ball is housed in a Railko bush inserted in the gear change
housing, the end of the lever locating in the selector yoke which is attached to the end of the selector shaft. Bias
springs provide a positive return of the gear lever to the neutral position with selection of 1st/2nd and 5th/reverse gears
being against bias spring pressure. Spring loaded detent balls fitted in the centre plate locate in grooves in the selector
shaft to provide positive gear and neutral selection.
Lubrication
Lubrication is by an oil pump located in the extension housing and driven by the layshaft with additional lubrication
being provided by splash. The pump directs oil via a filter and internal drillings in the output shaft to lubricate the
components. On non UK and non European models, provision for oil cooling is by means of a thermostat housed in
a cover bolted to the side of the extension housing. The cover incorporates tappings for connections to an oil cooler.
On UK and European models, the thermostat and cover are replaced by an oil by-pass block.
Internal pressures produced within the gearbox are vented to atmosphere via a plastic breather pipe. The pipe is
attached to the extension housing and is routed across the top of the gearcase and secured at the open end by a clip
attached to the engine cylinder block.
Selector shaft and forks
Selector forks for 1st/2nd, 3rd/4th and 5th/reverse gears are located on a single selector shaft; the 1st/2nd and 3rd/
4th selector forks are inside the main gearcase whilst the 5th/reverse selector fork is inside the extension housing.
Each of the selector forks locates inside its corresponding synchromesh hub.
Synchromesh assemblies
Each synchromesh assembly is located on the output shaft adjacent to its corresponding gears and comprises a
synchromesh ring, hub, slippers and sleeve. The hubs and slippers are retained in the sleeves by means of spring
clips. 1st/2nd and 3rd synchromesh assemblies are fitted with double synchromesh rings whilst 4th, 5th and reverse
assemblies are fitted with single rings.
The gear train
The gear train comprises an input shaft, output shaft, layshaft and reverse idler shaft together with their appropriate
gears and synchromesh assemblies.
The gear train input shaft, output shaft and layshaft are supported by taper roller bearings with all gears on the input
and output shafts running on caged needle roller bearings. Layshaft gears are integral with the shaft with the
exception of reverse/5th gears which are splined to the shaft and retained with a nut. 1st, 2nd, 3rd and 4th gears are
shot peened to improve durability. The reverse idler shaft and gear are supported in the centre plate by a caged
needle roller bearing. End-float of the output shaft and layshaft is controlled by selective shims located in the centre
plate whilst reverse idler shaft end-float is controlled by a selective shim located behind reverse gear.

MANUAL GEARBOX - R380
REPAIRS 37-15
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.
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
37-18 REPAIRS
22.Ensure gear lever is released from grommet
and no wires or pipes are trapped when
gearbox is lowered.
23.Remove clevis pin and 'C' washer securing low
ratio selector cable to lever and release cable
from lever housing.
24.Remove 2 cable ties securing cable to fuel
pipes. 25.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
26.Remove banjo bolts securing breather pipes
and discard sealing washers.
27.Remove bolt securing breather pipe 'P' clip and
release breather pipes.
28. If fitted: Disconnect 2 Lucars from differential
lock switch, release and disconnect transfer
box neutral sensor multiplug. Release harness
from 2 retaining clips.
29.Position container to catch oil spillage
30.Remove 2 bolts securing oil cooling pipe
housing to gearbox, release housing and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
31.Using a second jack support the weight of the
engine.

MANUAL GEARBOX - R380
REPAIRS 37-19
32.Remove 8 bolts securing gearbox to engine.
33.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.With assistance raise gearbox on jack and
align to clutch and engine.
3.Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4.Clean oil cooling pipe housing mating faces.
5.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6.Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8.Position breather pipes and secure 'P' clip with
bolt.
9.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12.Secure cable to fuel pipes with new cable ties.
13.Raise gearbox, ensuring gear change lever is
located in grommet.
14.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15.Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16.Remove 3 bolts securing support plate to
gearbox. 17.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18.Clean handbrake back plate and mating face.
19.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20.Clean handbrake drum.
21.Fit handbrake drum and tighten retaining
screw.
22.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front..
23.Fit rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
24.Clean exhaust silencer and tail pipe mating
faces.
25.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
27.Refit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
28.Refill gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
29.Refill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31.Fit gear lever trim and gear change knob.
32.Connect battery earth lead.
33.Fit cooling fan cowl and battery cover and
secure fixings.

MANUAL GEARBOX - R380
REPAIRS 37-23
Cooler - oil - gearbox - Diesel
$% 37.24.02
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, 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.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
4.Top up gearbox oil level.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.

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 -
engine oil.
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 -
engine oil.
4.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.

TRANSFER BOX - LT230SE
41-16 DESCRIPTION AND OPERATION
Differential lock warning lamp switch - if fitted - Vehicles up to 03 model year
A differential lock warning lamp switch connected to the SLABS ECU and operated by movement of the selector fork
and shaft is screwed into the top of the output housing. The switch connects to earth when the differential lock is
engaged.
Differential lock warning lamp switches - Vehicles from 03 model year
Vehicles from 03 model year are fitted with two differential lock warning lamp switches.
Both switches are of a new design and are fitted into the top of the front output housing. The switches are connected
to the SLABS ECU and are operated by movement of the selector shaft.
Both switches have an aluminium washer which seals the switch to the casing and also sets the switch position,
removing the requirement for a setting procedure.
Both switches are connected in parallel to earth when the differential lock is engaged. This earth is sensed by the
SLABS ECU which illuminates the differential lock warning lamp in the instrument pack.
Differential lock warning lamp - Vehicles up to 03 model year – if fitted
The differential lock warning lamp is located in the instrument pack and provides a warning to the driver when the
ignition is switched on that the differential lock is engaged. The warning lamp illuminates in a Red colour.
With the lock engaged, the traction control and electronic brake distribution warning lamps will also be illuminated.
Disengagement of the differential lock should be carried out with the ignition switched off. The warning lamps must
be extinguished when the ignition is switched on again.
Differential lock warning lamp – vehicles from 03 model year
The differential lock warning lamp is amber coloured and is located in the instrument pack.
When the lock is engaged, the warning lamp is illuminated and the instrument pack sounder emits three audible
chimes. When the lock is disengaged, the warning lamp is extinguished and the instrument pack sounder emits three
audible chimes.
Rear output housing
The rear output housing carries the output shaft and flange. A cable operated transmission brake is attached to the
housing, the brake drum being attached to the output flange.
The rear output shaft is supported in the housing by a single bearing and is splined into the differential rear sun gear.
Lubrication
Lubrication is by splash, oil filler/level and drain plugs being located in the main casing.
Internal pressures caused by thermal expansion and contraction are avoided by the use of a plastic breather pipe
venting the interior of the box to atmosphere. The pipe is attached to the top of the high/low selector housing by a
banjo bolt and is then routed in a continuously rising path into the engine compartment where the open end is secured
by a clip attached to the engine cylinder block.
Oil temperature warning lamp switch
An oil temperature switch is fitted to V8 engine models up to 03 Model Year. In the event of the transfer box oil
approaching maximum recommended working temperature of 145°C (293°F), the switch will close and a warning
lamp in the instrument pack will be illuminated.

TRANSFER BOX - LT230SE
REPAIRS 41-31
21. 03 Model Year onwards - if fitted: Release
and disconnect both differential lock warning
lamp switch multiplugs from main harness.
22.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
23.Position gearbox support jack and secure
support plate to jack using 4 bolts. 24.Remove 3 bolts securing transfer box to
gearbox.
25.Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
26.Remove 2 bolts and nut securing transfer box
to gearbox case.
CAUTION: If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
27.Position a jack to support gearbox and engine.
28.Remove 4 bolts and nut securing RH mounting
to body and transfer box.
29.Remove nut securing LH mounting to body.
30.Raise gearbox and remove RH mounting.
31.With assistance, remove transfer box from
gearbox.
32.Remove input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.