1999 LAND ROVER DISCOVERY tow

MANUAL GEARBOX - R380
37-46 OVERHAUL
Bearing - layshaft rear support
$% 37.20.58
Disassembly
1.Remove extension housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove 3 Torx screws, remove oil pump and
discard 'O' ring.
3.Drift out layshaft support bearing.
4.Using a suitable two legged puller remove 5th
gear layshaft support bearing track from end of
layshaft. Reassembly
1.Clean layshaft and bearing recess in extension
housing.
2.Fit layshaft support bearing.
3.Clean oil pump recess in extension housing,
ensure screw holes are clean and dry.
4.Lubricate oil pump recess in housing with
gearbox oil.
5.Lubricate a new 'O' ring with gearbox oil and fit
to oil pump.
6.Locate oil pump in extension housing with word
'TOP' towards top of housing.
7.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.
8.Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
9.Apply a small amount of heat and fit support
bearing track to layshaft.
10.Fit extension housing.

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

MANUAL GEARBOX - R380
37-52 OVERHAUL
Reassembly
1.Clean components.
2.Apply multi-purpose grease to ball and cross
pins.
3.Apply multi-purpose to new Railko bush and fit
to housing ensuring that slots are correctly
aligned.
4.Lubricate a new seal with gearbox oil and fit, lip
side towards housing using a suitable mandrel.
5.Position lower gear lever to selector housing
ensuring cross pins are located in Railko bush.
6.Position bias spring adjustment plate to
selector housing.
7.Clean threads of bias spring adjustment plate
bolts and apply sealant, Part No. STC 50552 to
threads.
8.Fit 2 short bolts to secure front of adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9.Position right hand bias spring to pillar ensuring
longest end of spring is against gear lever.
10.Restrain bias spring using a suitable pair of
grips, ensure shortest end of spring is on
outside edge of bolt hole.
11.Fit longest bolt and washer ensuring end of
bias spring is under washer, tighten bolt to 25
Nm (18 lbf.ft).
12.Repeat above procedures for remaining bias
spring.
13.Fit gear selector housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
14.Adjust gear lever bias springs.

+ MANUAL GEARBOX - R380,
ADJUSTMENTS, Spring - gear lever bias.
Housing - clutch
$% 37.12.07
Disassembly
1.Remove clutch release bearing and operating
lever.
2.Remove 6 bolts and remove clutch housing.
Reassembly
1.Clean clutch housing and gearbox mating face.
2.Position clutch housing and tighten bolts to 75
Nm (55 lbf.ft).
3.Fit clutch operating lever and release bearing.

TRANSFER BOX - LT230SE
41-34 REPAIRS
Switch - differential lock - Up to 03 MY
$% 41.20.34
Remove
1.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
2.Disconnect 2 Lucars from switch.
3.Remove switch and remove nut from switch.Refit
1.Clean switch and gearbox face.
2.Fit nut to switch with counterbore positioned
towards switch head. The nut acts as a spacer
to ensure that switch setting is correct.
Always ensure that nut is fully tightened to
switch head, (no gap).
3.Apply sealant, Part No. STC 50552 to switch
thread.
4.Position switch into front output housing until
nut bottoms out on housing.
5.Tighten nut securing differential lock switch to
11 Nm (8 lbf.ft)
6.Connect Lucars to switch.
7.Fit front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.

TRANSFER BOX - LT230SE
OVERHAUL 41-57
Refit
1.Clean differential components. Remove all
traces of sealant from housings and bolts,
differential lock warning lamp switches and
detent plugs.
2.Lubricate components with gearbox oil.
3.Position differential in soft jawed vice and fit
front bearing using tool LRT-41-008. 4.Invert differential in soft jawed vice, and fit low
range gear with dog teeth facing uppermost.
5.Fit high/low hub ensuring that machined
groove on hub teeth faces towards low range
gear.
6.Fit high/low selector sleeve ensuring that
alignment marks on hub and sleeve are
together.
7.Fit bush to high range gear ensuring collar is
uppermost.
8.Fit high range gear and bush onto shaft.
9.Fit new rear bearing using tool LRT-41-008.

TRANSFER BOX - LT230SE
OVERHAUL 41-61
41.Position selected shim in front output housing
and using tool LRT-54-003, fit new differential
front bearing track.
42.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
43. If fitted: Fit dog clutch with flange on clutch
facing towards splined end.
44.Using a copper mallet, drive output shaft into
bearing.
Note: Carry out the following operations for
transfer boxes fitted with differential lock.
45.Compress differential lock selector spring and
fit selector fork.
46.Position selector fork to groove in dog clutch.
47.Fit selector shaft and locate in housing recess,
rotate shaft until the two flats for retaining clips
are at right angles to the cover plate mating
face. 48.Compress selector spring and fit retaining clips
at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess of clips.
49.Apply sealant, Part No. STC 4600 to front
output shaft housing.
50.Position housing ensuring that output shaft and
dog clutch splines - if fitted are correctly
engaged.
51.Clean output shaft housing bolt threads.
52.Apply sealant, Part No. STC 50552 to threads
of bolts.
53.Fit output shaft housing bolts and tighten in a
diagonal sequence to 45 Nm (33 lbf.ft).
54.Apply sealant, Part No. STC 4600 to mating
face of high/low selector housing.
55.Position high/low selector housing to front
output housing ensuring that high/low selector
finger is located in groove in selector shaft.
56. 03 Model Year onwards: Position multiplug
and selector cable brackets to high/low selector
housing
57.Apply sealant, Part No. STC 50552 to threads
of selector housing bolts.
58. Up to 03 Model Year: Fit bolts and tighten to
25 Nm (18 lbf.ft).
59.Fit differential lock detent ball and spring.
60.Apply sealant, Part No. STC 50552 to threads
of differential lock detent plug.
61. 03 Model Year onwards - differential lock
fitted: Fit and tighten detent plug, then loosen
2 complete turns.
62. 03 Model Year onwards - differential lock
fitted: Apply sealant, Part No. STC 50552 to
threads of differential lock detent plug.
63. 03 Model Year onwards - differential lock
fitted: Fit detent ball and spring.

TRANSFER BOX - LT230SE
41-62 OVERHAUL
64. 03 Model Year onwards - differential lock
fitted: Fit differential lock detent plug and
tighten until head of plug is level with face of
output shaft housing.
65. 03 Model Year onwards - differential lock
fitted: Using a straight edge, check that head
of plug is correctly positioned, screw plug in or
out as necessary.
66. 03 Model Year onwards - differential lock
fitted: Lubricate and fit new 'O' rings to
differential lock selector housing.
67. 03 Model Year onwards - differential lock
fitted: Fit selector housing, ensure selector
finger is located in shaft recess.
68. 03 Model Year onwards: Position cable
bracket to selector housing.
69. Apply sealant, Part No. STC 50552 to threads
of selector housing bolts, fit bolts and tighten to
25 Nm (18 lbf.ft).70. Up to 03 Model Year - differential lock fitted:
Fit nut to differential lock warning lamp switch
with counterbore positioned towards switch
head. The nut acts as a spacer to ensure
that switch setting is correct. Always
ensure that nut is fully tightened to switch
head (no gap).
71.Apply sealant, Part No. STC 50552 to threads
of differential warning lamp switch.
72.Position switch into front output housing until
nut bottoms out on housing; tighten nut to 11
Nm (8 lbf.ft)
73. 03 Model Year onwards - differential lock
fitted: Fit new aluminium sealing washers to
differential lock warning lamp switches.
CAUTION: Ensure that replacement
washers are the same thickness as the
originals.
74. 03 Model Year onwards - differential lock
fitted: Apply sealant, Part No. STC 50552 to
threads of switches.
75. 03 Model Year onwards - differential lock
fitted: Fit switches and tighten to 25 Nm (18
lbf.ft).
76.Fit output flange, new felt washer, steel washer
and new retaining nut.
M41 7886

TRANSFER BOX - LT230SE
41-66 OVERHAUL
4.Fit bearing spacer to output shaft with chamfer
on spacer towards threaded end.
5.Fit dog clutch with flange on clutch facing
towards splined end.
6.Using a copper mallet, drive output shaft into
bearing.
7.Compress differential lock selector spring and
fit selector fork.
8.Position selector fork to groove in dog clutch.
9.Fit differential lock selector shaft and locate in
housing recess, rotate shaft until the two flats
for retaining clips are at right angles to the
cover plate mating face.
10.Compress differential lock selector spring and
fit retaining clips at each end of spring.
CAUTION: Ensure ends of spring are fully
seated in recess in clips.
11.Apply sealant, Part No. STC 4600 to front
output shaft housing.
12.Position housing ensuring that output shaft and
dog clutch splines are correctly engaged.
13.Apply sealant, Part No. STC 50552 to threads
of bolts.
14.Fit front output shaft housing bolts and tighten
in a diagonal sequence to 45 Nm (33 lbf.ft).
15.Apply sealant, Part No. STC 4600 to mating
face of high/low selector housing.
16.Position high/low selector housing to front
output housing ensuring that high/low selector
finger is located in groove in selector shaft.
17. Position multiplug and selector cable brackets
to high/low selector housing
18.Apply sealant, Part No. STC 50552 to threads
of high/low selector housing bolts.
19.Fit bolts and tighten to 25 Nm (18 lbf.ft).20.Fit differential lock detent ball and spring.
21. Up to 03 Model Year: Apply sealant, Part No.
STC 50552 to threads of detent plug.
22. Up to 03 Model Year: Fit and tighten detent
plug, then unscrew 2 complete turns.
23. 03 Model Year onwards: Apply sealant, Part
No. STC 50552 to threads of differential lock
detent plug.
24.Fit differential lock detent ball and spring.
25.Fit detent plug and tighten until head of plug is
level with face of housing.
26.Using a suitable straight edge, check that head
of plug is correctly positioned, screw plug in or
out as necessary.
27.Lubricate and fit new 'O' rings to differential lock
selector housing.
28.Fit selector housing, ensure selector finger is
located in shaft recess.
29.Position bracket to selector housing.
30.Apply sealant, Part No. STC 50552 to threads
of selector housing bolts, fit bolts and tighten to
25 Nm (18 lbf.ft).
M41 7886

TRANSFER BOX - LT230SE
OVERHAUL 41-67
31.Clean threads of differential lock warning lamp
switch(es).
32. Uo to 03 Model year: Fit nut to switch head
with counterbore positioned towards switch
head. The nut acts as a spacer to ensure
that switch setting is correct. Always
ensure that nut is fully tightened to switch
head (no gap).
33. Uo to 03 Model year: Apply sealant, Part No.
STC 50552 to threads of differential warning
lamp switch.
34. Uo to 03 Model year: Position switch into front
output housing until nut bottoms out on
housing, tighten nut to 11 Nm (8 lbf.ft).
35. 03 Model Year onwards: Fit new aluminium
sealing washers to differential lock warning
lamp switches.
CAUTION: Ensure that replacement
washers are the same thickness as the
originals.
36. 03 Model Year onwards: Apply sealant, Part
No. STC 50552 to threads of both switches.
37. 03 Model Year onwards: Fit switches and
tighten to 25 Nm (18 lbf.ft).
38. If fitted: Operate differential lock selector lever
and check that detent ball can be felt to
positively engage/disengage with grooves in
shaft.
39. Up to 03 Model Year: Screw plug in or out until
setting is correct
40.Apply sealant, Part No. STC 4600 to mating
face of differential lock selector side cover.
41.Apply sealant, Part No. STC 50552 to threads
of side cover bolts.
42.Position differential lock selector side cover to
front output shaft housing, fit bolts and tighten
25 Nm (18 lbf.ft).43.Fit output flange, new felt and steel washers
and new retaining nut.
44.Using tool LRT-51-003 to restrain flange,
tighten output flange nut to 162 Nm (119 lbf.ft).