1999 LAND ROVER DISCOVERY oil filter

ENGINE MANAGEMENT SYSTEM - V8
18-2-84 REPAIRS
Sensor - radiator temperature
$% 18.30.20
Remove
1.Disconnect battery earth lead.
2.Position container to collect coolant spillage.
3.Disconnect multiplug from sensor.
4.Remove sensor and discard sealing washer.
Refit
1.Fit new sealing washer to sensor.
2.Fit and tighten sensor.
3.Connect multiplug to sensor.
4.Refill cooling system.
5.Connect battery earth lead.
Sensor - camshaft position (CMP)
$% 18.30.24
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Release fixings and remove underbelly panel.
5.Remove engine oil filter.

+ ENGINE - V8, REPAIRS, Filter - oil.
6.Disconnect engine harness from CMP sensor
and release CMP sensor multiplug from
bracket.
7.Remove bolt from clamp securing CMP sensor
to timing gear cover.
8.Remove clamp and CMP sensor. Discard 'O'
ring from CMP sensor.
Refit
1.Ensure CMP sensor is clean, fit new 'O' ring
and sensor to cover.
2.Fit clamp to CMP sensor and tighten bolt to 8
Nm (6 lbf.ft).
3.Fit sensor multiplug to bracket and connect
engine harness to multiplug.
4.Fit engine oil filter.

+ ENGINE - V8, REPAIRS, Filter - oil.
5.Fit underbelly panel and secure with fixings.
6.Lower vehicle and connect battery earth lead.
7.Fit battery cover and secure with fixings.

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-3
1Front cover
2Input shaft oil seal
3Oil filler/level plug
4Sealing washer
5Oil drain plug
6Gear case
7Interlock spool retainer, bolt and 'O' ring
8Centre plate
9Locating dowels
10Selector plug, detent balls and spring
11Splash shield and retaining bolt
12Extension housing
13Gate plate and retaining bolt
14Interlock spool retainer, retaining bolt and 'O'
ring – if fitted – extension housing
15Inhibitor cam spring
16Inhibitor cam
17Reverse inhibitor shaft
18Output shaft oil seal
19Oil seal collar
20Oil pump and retaining bolt
21'O' ring
22Reverse lamp switch23Oil by-pass block - UK and European models
24Bolt - oil by-pass block
25'O' ring - oil by-pass block
26Thermostat and housing - non UK and non
European models
27'O' ring - thermostat housing
28Bolt - thermostat housing
29Oil pick-up pipe
30Oil filter
31Oil pick-up ring
32Rubber gaiter
33Cable tie
34Upper gear lever
35Clamp bolt
36Bias springs
37Bolts and washers - bias adjusting plate and
housing
38Bias adjusting plate
39Lower gear lever and ball
40Railko bush
41Oil seal
42Gear change housing

MANUAL GEARBOX - R380
37-6 DESCRIPTION AND OPERATION
R380 gearbox cross section
1Input shaft
2Breather
3Input shaft 4th gear
4Selector shaft
53rd/4th selector fork
6Output shaft 3rd gear
7Output shaft 2nd gear
81st/2nd selector fork
9Output shaft 1st gear
10Selective shims - output shaft and layshaft end-
float
11Selective shim - reverse gear idler shaft end-
float
125th/reverse selector fork
13Selector yoke14Gear change assembly
15Railko bush
16Output shaft 5th gear
17Output shaft oil seal
18Output shaft
19Oil pump
205th/reverse gear synchromesh assembly
21Output shaft reverse gear
22Centre plate
23Oil filter
241st/2nd synchromesh assembly
25Layshaft
263rd/4th gear synchromesh assembly
27Input shaft oil seal

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
OVERHAUL 37-41
Pump - gearbox oil
$% 37.12.47
Disassembly
1.Remove gearbox extension.

+ MANUAL GEARBOX - R380,
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,
OVERHAUL, Extension - gearbox rear.
Filter - gearbox oil
$% 37.12.38
Disassembly
1.Remove gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove oil filter from gearbox.
Reassembly
1.Clean filter recess in gearbox.
2.Fit filter.
3.Fit gearbox extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.

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.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-48 REPAIRS
Filter - oil
$% 44.24.07
Remove
1.Remove oil sump gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - oil sump.
2.Remove Torx screw securing oil pick-up tube
and remove tube.
3.Remove 2 Torx screws securing filter to valve
body and discard 'O' rings. Refit
1.Clean filter and pick-up tube using a lint free
cloth.
2.Fit new 'O' rings to filter.
3.Position filter and tighten Torx screws to 8 Nm
(6 lbf.ft).
4.Position oil pick-up tube and tighten Torx
screw to 8 Nm (6 lbf.ft).
5.Fit oil sump gasket.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Gasket - oil sump.

AUTOMATIC GEARBOX - ZF4HP22 - 24
REPAIRS 44-51
Valve body assembly
$% 44.40.01
Remove
1.Remove gearbox oil filter.

+ AUTOMATIC GEARBOX - ZF4HP22
- 24, REPAIRS, Filter - oil.
2.Remove 2 bolts securing speed sensor
harness bracket to valve body.
3.Disconnect multiplug from gearbox housing.
4.Using a 30 mm socket, remove nut securing
multiplug connector block to gearbox housing. 5.Remove 6 long bolts securing valve body to
gearbox.
6.Remove 5 short bolts securing valve body to
gearbox.