1999 LAND ROVER DISCOVERY Workshop Manual

MANUAL GEARBOX - R380
37-34 OVERHAUL
Fork - set - selector shaft
$% 37.16.45
Disassembly
1.Remove reverse idler gear shaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, Shaft - reverse idler.
2.With assistance, remove output shaft, selector
shaft and layshaft assemblies.
3.Remove selector shaft and fork assembly from
output shaft synchronisers.
4.Inspect the selector fork pads for wear, the
wear limit is 6.5 mm (2.559 in).Reassembly
1.Clean selector shaft, forks and locations on
synchronisers.
2.Lubricate forks and shaft with clean gear oil.
3.Position selector shaft assembly to output shaft
synchronisers.
4.With assistance, fit output shaft and layshaft
assembly into gearbox case.
5.Fit reverse idler gear shaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, Shaft - reverse idler.

MANUAL GEARBOX - R380
OVERHAUL 37-35
Shaft - gearbox - input
$% 37.20.16
Disassembly
1.Remove gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.
2.Remove reverse idler gear shaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, Shaft - reverse idler.
3.With assistance, remove output shaft, selector
shaft and layshaft as an assembly. Remove
selector shaft and fork. 4.Remove input shaft from gearbox case.
5.Using tool LRT-37-004, and LRT-99-004,
remove pilot bearing track from input shaft.

MANUAL GEARBOX - R380
37-36 OVERHAUL
6.Invert output shaft and using tool LRT- 99-002
and support bars under 3rd gear, press off pilot
bearing.7.Using tool LRT-37-043 and LRT-99-002,
remove taper roller bearing from input shaft.
8.Using a suitable soft metal drift, remove
bearing outer track from front cover.
9.Remove and discard input shaft oil seal from
front cover.

MANUAL GEARBOX - R380
OVERHAUL 37-37
Reassembly
1.Clean input shaft and bearing/oil seal recess in
front cover.
2.Lubricate a new input shaft oil seal with
gearbox oil.
3.Fit oil seal using a suitable mandrel.
4.Using a press and a suitable mandrel, fit
bearing outer track in front cover.
5.Using a press and a suitable mandrel, fit pilot
bearing outer track to input shaft.
6.Using tool LRT-37-043, LRT-37–043/2 and
LRT-99-002, fit new taper bearing to input
shaft.7.Using tool LRT-99-002 and a suitable mandrel,
press new pilot bearing onto output shaft.
8.Position input shaft to gearbox case.
9.With assistance, fit output shaft and layshaft
assembly into gearbox case.
10.Fit reverse idler gear shaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, Shaft - reverse idler.
11.Fit gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.

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
OVERHAUL 37-39
6.Fit 2 off 8x35 mm slave bolts to secure centre
plate to gearbox casing.
7.Remove 3 Torx screws, remove oil pump and
discard 'O' ring.
8.Drift out layshaft support bearing.
9.Remove and discard output shaft rear oil seal.
10.Remove oil pick-up pipe. 11.Drift out output shaft support bearing and oil
pick-up ring.
12.Remove reverse inhibitor shaft, cam and
spring.
13.Remove 2 bolts and remove gate plate.
14.Remove reverse light switch and discard
sealing washer.
15.Remove 2 bolts, remove oil cooler by-pass and
discard 'O' rings.
Reassembly
1.Clean extension housing and mating faces.
2.Clean oil cooler by-pass.
3.Using new 'O' rings, fit oil cooler by-pass and
tighten bolts to 15 Nm (11 lbf.ft).
4.Using new sealing washer, fit reverse light
switch and tighten to 24 Nm (17 lbf.ft).
5.Fit reverse inhibitor spring and cam.
6.Clean threads of reverse inhibitor shaft and
gate plate bolts.
7.Apply sealant, Part No. STC 50552 to threads
of reverse inhibitor shaft, fit and tighten shaft.
8.Apply sealant, Part No. STC 50552 to threads
of gate plate bolts.
9.Position gate plate and tighten bolts to 15 Nm
(11 lbf.ft).
10.Fit output shaft support bearing and oil pick-up
ring. Align tag with centre of drain slot.
11.Fit layshaft support bearing.

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 37-41
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.