2002 LAND ROVER DISCOVERY light

MANUAL GEARBOX - R380
OVERHAUL 37-37
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 3254 to gearbox
casing face.
21.Position extension housing, align oil pump drive
with layshaft.
22.Clean extension housing bolt threads.
23.Apply Loctite 290 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 3254 to gear
selector housing face.
28.Position gear selector housing and tighten
bolts to 25 Nm (18 lbf.ft).
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.

MANUAL GEARBOX - R380
37-42 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.

TRANSFER BOX - LT230SE
ADJUSTMENTS 41-21
ADJUST ME NTS
Cable - high/low selector
$% 41.20.46
Adjust
1.Raise vehicle on ramp.
2.Using a suitable crows foot spanner, loosen
lock nuts securing outer cable to abutment
bracket.
3.Select high range by moving lever on transfer
gearbox fully forward.
4.Insert tool LRT-41-016 through hole in selector
lever and housing. This ensures selector
lever is in the high range position.
5.Lightly tighten outer cable lock nuts.
6.Remove tool LRT-41-016 from gear selector
lever and housing.
7.Simultaneously tighten high/low selector cable
lock nuts either side of abutment bracket to 30
Nm (22 lbf.ft) .
8.Lower vehicle on ramp.

TRANSFER BOX - LT230SE
REPAIRS 41-25
12. If fitted: Disconnect 2 Lucars from differential
lock switch and disconnect multiplug from
reverse light switch.
13.Remove cable tie and multi plug from bracket
on transfer box.
14.Release transfer box breather pipe from
bulkhead clip.
15.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
16.Position gearbox support jack and secure
support plate to jack using 4 bolts. 17.Remove 3 bolts securing transfer box to
gearbox.
18.Fit 3 guide studs LRT-41-009 through
transfer box bolt holes to support it during
removal.
19.Remove 2 bolts and nut securing transfer box
to gearbox. CAUTION: If securing stud is
removed during this operation, it must be
discarded and a new stud fitted.
20.Position a jack to support gearbox and engine.
21.Remove 4 bolts and nut, remove gearbox RH
mounting.
22.With assistance, remove transfer box from
gearbox.
23.Remove input shaft oil seal.

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

TRANSFER BOX - LT230SE
41-26 REPAIRS
Refit
1.Fit new input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
2.Clean transfer box to gearbox mating faces.
3.Raise transfer box on jack and align to guide
studs LRT-41-009.
4.Clean transfer box to gearbox bolt threads.
5.Apply Loctite 290 to bolt and stud threads.
6.Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted, apply Loctite 290 to stud threads and
tighten to 45 Nm (33 lbf.ft).
7.Remove guide studs, fit and lightly tighten
remaining 3 bolts.
8.Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft).
9.Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10.Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11.Remove 4 bolts securing support plate to
gearbox jack.
12.Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
13.Clean bottom plate bolt threads.
14.Apply Loctite 290 to threads of 4 bottom plate
bolts.
15.Fit 4 bolts securing bottom plate to transfer box
and tighten to 25 Nm (18 lbf.ft).
16.Position breather pipe and secure to bulkhead
clip.
17.Connect multiplug to reverse light switch.
18. If fitted - Connect Lucars to differential lock
switch.
19.Fit multiplug and cable tie to transfer gearbox
bracket. 20.Position high/low ratio selector cable and
secure with clevis pin.
21.Clean handbrake and mating face.
22.Position handbrake back plate and tighten
bolts to 75 Nm (55 lbf.ft).
23.Clean handbrake drum.
24.Fit handbrake drum and tighten retaining
screw.
25.Fit front propeller shaft.

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

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
27.Clean exhaust silencer and mating face.
28.Position silencer, fit new gasket , connect
mounting rubbers and tighten nuts to 40 Nm
(30 lbf.ft).
29.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.

TRANSFER BOX - LT230SE
REPAIRS 41-29
22.Remove 4 bolts and nut securing RH mounting
to body and transfer box.
23.Remove nut securing LH mounting to body.
24.Raise gearbox and remove RH mounting.
25.With assistance, remove transfer box from
gearbox.
26.Remove input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
Refit
1.Fit new input shaft oil seal.

+ TRANSFER BOX - LT230SE,
REPAIRS, Oil seal - input shaft.
2.Clean transfer box to gearbox mating faces.
3.Raise transfer box on jack and align to guide
studs LRT-41-009.
4.Clean transfer box to gearbox bolt threads.
5.Apply Loctite 290 to bolt and stud threads.
6.Fit and lightly tighten 2 bolts and nut securing
transfer box to gearbox. If new stud is to be
fitted apply Loctite 290 to threads of stud
and tighten to 45 Nm (33 lbf.ft)
7.Remove guide studs, fit and lightly tighten 3
bolts.
8.Tighten bolts and nut by diagonal selection to
45 Nm (33 lbf.ft.
9.Position gearbox RH mounting and tighten
bolts to 85 Nm (63 lbf.ft).
10.Tighten gearbox RH mounting nut to 48 Nm
(35 lbf.ft).
11.Fit nut to LH mounting and tighten to 48 Nm (35
lbf.ft).
12.Remove 4 bolts securing support plate to
gearbox jack.
13.Remove 4 bolts securing support plate LRT-99-
010 to transfer box and remove plate.
14.Clean threads of bottom plate bolts.
15.Apply Loctite 290 to threads of bolts.
16.Fit 4 bolts securing bottom plate and tighten to
25 Nm (18 lbf.ft).
17.Using new washers position breather pipe and
tighten banjo bolt.
18.Connect multiplug to transfer box neutral switch
and secure harness. 19. If fitted - Connect Lucars to differential lock
switch.
20.Connect multiplug and Lucars to reverse lamp
switch and oil temperature sensor.
21.Position high/low ratio selector cable and
secure with 'C' washer and clevis pin.
22.Secure cable to fuel pipes with new cable ties.
23.Clean handbrake back plate and mating face.
24.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
25.Clean handbrake drum.
26.Fit handbrake drum and tighten retaining
screw.
27.Fit front propeller shaft.

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

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
29.Clean exhaust silencer and tail pipe mating
faces.
30.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
31.Position rear cross member, fit bolts and
tighten to 26 Nm (19 lbf.ft).
32.Refill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
33.Fit front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.

TRANSFER BOX - LT230SE
OVERHAUL 41-49
19.Check width of high/low selector groove.
lGroove width = 16.0 to 16.1 mm (0.63 to
0.64 in).
20.Check high/low selector fork for cracks and
wear. Check selector fork finger width.
lFinger width = 7.37 to 7.47 mm (0.290 to
0.294 in).
21.03 MY onwards: Check high/low selector fork
clips for wear and damage. Check spring for
distortion, check free length of spring:
lSpring free length = 75 mm (2.95 in)
Note: High/low selector shaft, fork and spring
fitted to 03 MY transfer boxes may be fitted to
pre 03 MY boxes as an assembly.
22.Check differential sun and planet gears for
wear, cracks and chipping of teeth.
23.Check cross shafts and recesses in both halves
of differential carrier for damage and
wear.Ensure planet gears are retained with
their respective shafts.
24.Check retaining ring for distortion.
25.Check differential splines for wear and
damage.26.Check high/low hub for cracks, chipping and
uneven wear. Check width of selector fork
groove.
lGroove width = 7.5 to 7.6 mm (0.295 to 0.30
in).
27.Check splines and teeth on high/low selector
sleeve for uneven wear, cracks, damage and
chipping.
28.Check teeth of high and low range gears for
cracks, chipping and uneven wear.
29.Check high range gear bush for wear and
damage.
Reassembly
1.Lubricate all components with recommended
oil and lightly oil the differential bolt threads.

REAR AXLE
OVERHAUL 51-13
22.Align setting gauge LRT-51-018/7 to setting
block, rock gauge to obtain minimum reading. If
reading is lower than required reading,
decrease shim size. If reading is higher than
required reading, increase shim size.
23.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer. Remove pinion
flange.
24.Remove pinion, collect tail bearing and tail
bearing shim.
25.Remove pinion head bearing outer race and
shim. Discard shim. Ensure bearing race
recess is clean and free from burrs.
26.Fit calculated shim, and using LRT-51-018/4 fit
head bearing outer race.
27.Fit pinion, pinion tail bearing and tail bearing
shim.
28.Fit pinion flange and bolt and washer. Using
LRT-51-003 to restrain pinion flange, tighten
bolt to 100 Nm (74 lbf.ft).
29.Rotate pinion in both directions to settle
bearings.
30.Recheck pinion Torque to Turn, adjust if
necessary.
31.Recheck pinion head height.
32.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer. Remove pinion
flange.
33.Discard bolt.34.Using LRT-51-010 fit pinion seal.
35.Ensure spacer and tail bearing are correctly
located.
36.Fit pinion, pinion flange and washer.
37.Fit new pinion flange bolt and tighten to 100 Nm
(74 lbf.ft).
38.Lightly oil differential bearings.
39.Ensure spring dowels are fitted in bearing caps.
40.Fit differential bearing outer races and locate
differential assembly into housing.
41.Fit bearing caps and tighten bolts to 10 Nm (7.5
lbf.ft).
42.Fit adjusting nuts, tighten crown wheel side nut
to 22 Nm (16 lbf.ft). Ensure opposing nut is
loose.
43.Position DTI to check crown wheel backlash.
Adjust opposing nut to obtain correct crown
wheel backlash.
44.Rotate pinion in both directions to settle
bearings.
45.Measure in 3 places to obtain correct crown
wheel backlash.
NOTE: Crown wheel backlash should be within
0.076 mm - 0.177 mm (0.003' - 0.007').
46.Align adjusting nuts to next roll pin slot, do not
loosen nuts to align slots.