1999 LAND ROVER DISCOVERY lock

MANUAL GEARBOX - R380
37-38 OVERHAUL
Extension - gearbox rear
$% 37.12.01
Disassembly
1.Remove 4 bolts and remove gear selector
housing.
2.Using tools LRT-37-009, LRT-37-001/2 and
LRT-37-010 , remove output shaft oil seal
collar.3.Remove bolt securing interlock spool retainer
and discard 'O' ring.
4.Noting fitted position of 2 longest bolts, remove
10 bolts securing extension housing to
gearbox.
5.Remove extension housing from gearbox
centre plate.

MANUAL GEARBOX - R380
37-40 OVERHAUL
12.Fit new output shaft oil seal using tool LRT-37-
014.
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 4404 to gearbox
casing face.
21.Position extension housing, align oil pump drive
with layshaft.
22.Clean extension housing bolt threads.
23.Apply sealant, Part No. STC 50552 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 4404 to gear
selector housing face.
28.Position gear selector housing and tighten
bolts to 25 Nm (18 lbf.ft).

MANUAL GEARBOX - R380
OVERHAUL 37-49
5.Remove 2 bolts securing spool retainer to
gearbox case. Remove retainer, remove and
discard 'O' ring - if fitted.
6.Remove interlock spool from selector shaft.
7.Remove filter from gearbox case.
8.Align selector shaft pin with slot in centre plate
and using wooden blocks and hide mallet,
release centre plate and collect lower detent
ball and spring. 9.Press out reverse idler shaft using a suitable
press.
10.Remove idler gear, needle roller bearing and
spacer.

MANUAL GEARBOX - R380
37-50 OVERHAUL
Reassembly
1.Clean centre plate and reverse gear
components.
2.Lubricate gearbox components with clean gear
oil.
3.Position idler gear, bearing and spacer to idler
shaft.
4.Using a suitable press fit idler shaft to centre
plate.
5.Using feeler gauges, check clearance between
reverse idler and shaft flange; fit a thicker or
thinner spacer if necessary in order to achieve
correct clearance:
lNew clearance = 0.04 - 0.38 mm (0.002 -
0.015 in)
lService limit = 0.38 mm (0.015 in)
6.Apply sealant, Part No. STC 4404 to gearbox
casing.
7.Fit lower spring and detent ball into centre
plate, retain using a dummy shaft.
8.Align selector shaft pin with slot in centre plate.
9.Fit centre plate and fit 2 off 8x35 mm slave bolts
to retain centre plate in position on gearbox
case; recover dummy shaft.
10.Fit filter to gearbox case.
11.Fit interlock spool to selector shaft.
12.Using new 'O' ring, fit spool retainer and tighten
bolts to 8 Nm (6 lbf.ft).
13.Clean threads of detent plug.
14.Apply sealant, Part No. STC 50552 to threads
of detent plug, fit upper detent ball and spring.
15.Fit detent plug and tighten to 25 Nm (18 lbf.ft).
16.Position reverse gear to layshaft.
17.Position reverse gear complete with bearing,
collar and selective spacer to output shaft.
18.Fit 5th / reverse gear synchroniser.

+ MANUAL GEARBOX - R380,
OVERHAUL, Synchronizer assembly - 5th/
reverse.
Housing - gear selector mechanism
$% 37.16.37.01
Disassembly
1.Remove 4 bolts and remove gear selector
housing.
Reassembly
1.Clean mating faces on selector housing and
gearbox.
2.Apply sealant, STC 4404 to selector housing.
3.Clean selector housing bolt threads.
4.Apply sealant, Part No. STC 50552 to threads
of selector housing bolts, position selector
housing and tighten bolts to 25 Nm (18 lbf.ft)
5.Adjust gear lever bias springs.

+ MANUAL GEARBOX - R380,
ADJUSTMENTS, Spring - gear lever bias.

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-3
1Rear output housing
2Differential rear bearing
3High range gear and bush
4Main casing
5High/low selector sleeve and hub
6Low range gear
7Differential assembly
8Front output housing
9Differential front bearing
10Selective shim - differential bearing pre-load
11Dog clutch - Differential lock
12Front output flange13Differential lock selector shaft - Differential lock
14Selector fork - Differential lock
15Front output shaft
16Selective spacer - intermediate gear bearing
pre-load
17Mainshaft input gear
18Selective shim - input gear bearing pre-load
19Intermediate shaft
20Intermediate gear cluster
21Rear output shaft
22Rear output flange

TRANSFER BOX - LT230SE
41-4 DESCRIPTION AND OPERATION
Main casing components – Vehicles up
to 03 model year
1Retaining plate
2Stake nut - intermediate shaft
3Bolt - retaining plate
4'O' rings - intermediate shaft
5Bearings and outer tracks - mainshaft input
gear
6Mainshaft input gear bearing housing
7Cover plate
8Bolt - cover plate
9Selective shim
10Mainshaft input gear
11Oil filler/level plug
12Oil temperature switch - if fitted
13Bearings and outer tracks - intermediate gears
14Circlips
15Intermediate gears
16Bottom cover plate
17Bolt - bottom cover plate
18Selective spacer19Mainshaft oil seal
20Oil drain plug
21Main casing
22Intermediate shaft
23Locating dowel
24Detent ball - high/low selector
25Detent spring - high/low selector
26Detent plug - high/low selector
27Neutral warning switch - Automatic gearbox
only - North America and Japan
28Bolt - interlock solenoid cover - Automatic
gearbox only - North America and Japan
29Cover - interlock solenoid - Automatic gearbox
only - North America and Japan
30Belleville washer - Automatic gearbox only -
North America and Japan
31Interlock solenoid - Automatic gearbox only -
North America and Japan

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-9
1Breather pipe, banjo bolt and sealing washers
2Bolt - high/low cross shaft housing and
abutment bracket
3Selector cable abutment bracket
4Multiplug bracket
5Hollow plug
6High/low cross shaft housing
7'O' ring
8High/low cross shaft and lever
9Front output shaft - Differential lock - If fitted
10Dog clutch - Differential lock - If fitted
11Warning lamp switch - Differential lock - If fitted
12Detent plug - Differential lock - If fitted
13Detent spring - Differential lock - If fitted
14Selector shaft - Differential lock - If fitted
15Detent ball - Differential lock - If fitted
16Threaded spacer - Differential lock - If fitted
17Front output housing
18Spring and clips - Differential lock - If fitted
19Bolt - cover plate
20Cover plate
21Selector fork - Differential lock - If fitted22Bolt - front output housing
23Hollow plug
24Circlip
25Front output flange
26Steel washer
27Self-locking nut
28Felt washer
29Oil seal
30Output shaft bearing
31Bearing spacer
32High/low detect switch
33Selector finger and shaft - Differential lock - If
fitted
34'O' rings - Differential lock - If fitted
35Bolt - selector housing - Differential lock - If
fitted
36Selector housing - Differential lock - If fitted
37High/low selector finger
38Front output shaft - Vehicles not fitted with
differential lock

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-11
1Breather pipe, banjo bolt and sealing washers
2Bolt - high/low cross shaft housing and
abutment bracket
3Selector cable abutment bracket
4Multiplug bracket
5Hollow plug
6High/low cross shaft housing
7'O' ring
8High/low cross shaft and lever
9Front output shaft
10Dog clutch - Differential lock
11Warning lamp switch - Differential lock
12Warning lamp switch - Differential lock
13Aluminium sealing washers
14Selector shaft - Differential lock
15Aluminium sealing washer
16Front output housing
17Spring and clips - Differential lock
18Bolt - cover plate
19Cover plate
20Selector fork - Differential lock
21Bolt - front output housing22Detent plug - Differential lock
23Detent spring - Differential lock
24Detent ball - Differential lock
25Hollow plug
26Circlip
27Front output flange
28Steel washer
29Self-locking nut
30Felt washer
31Oil seal
32Output shaft bearing
33Bearing spacer
34High/low detect switch
35Selector finger and shaft - Differential lock
36'O' rings - Differential lock
37Bolt - selector housing - Differential lock
38Selector housing - Differential lock
39High/low selector finger
40Washer
41Nut
42Differential lock selector lever