2002 LAND ROVER DISCOVERY sensor

CLUTCH - TD5
DESCRIPTION AND OPERATION 33-1-7
Dual mass flywheel
1Ring gear
2Primary flywheel
3Inner drive plate
4Spring housing
5Secondary flywheel
6Rivet
7Ball bearing8Dowel location hole
9Mounting hole
10Inner spring
11Outer spring
12Crankshaft position sensing holes
13Pressure plate locating dowel
The dual mass flywheel is bolted on the rear of the crankshaft with eight bolts. A dowel on the crankshaft flange
ensures that the flywheel is correctly located. A ring gear is fitted on the outer diameter of the flywheel. The ring gear
is not serviceable. Thirty blind holes are drilled in the outer diameter of the flywheel adjacent to the ring gear. The
holes are positioned at 10
° intervals with four 20° spaces. The holes are used by the crankshaft position sensor for
engine management.

+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.

CLUTCH - V8
DESCRIPTION AND OPERATION 33-2-7
Flywheel
The flywheel is bolted to a flange on the rear of the crankshaft with six bolts. A dowel on the crankshaft flange ensures
that the flywheel is correctly located. A ring gear is fitted on the outside diameter of the flywheel and seats against a
flange. The ring gear is an interference fit on the flywheel and is installed by heating the ring and cooling the flywheel.
The ring gear is a serviceable item and can be replaced if damaged or worn.
The operating face of the flywheel is machined to provide a smooth surface for the drive plate to engage on. Three
dowels and six threaded holes provide for the location and attachment of the pressure plate. The flywheel is balanced
to ensure that it does not produce vibration when rotating. A machined slot, with a series of holes within the slot, is
located on the engine side of the flywheel. The slot accommodates the tip of the crankshaft position sensor which is
used by the Engine Control Module (ECM) for engine management.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
Pressure plate
1Leaf spring
2Fulcrum ring
3Fulcrum ring
4Drive plate
5Pressure plate6Diaphragm
7Cover
8Rivet
9Retractor clip
The pressure plate assembly comprises a pressure plate, cover and diaphragm and is mounted on and rotates with
the flywheel.

MANUAL GEARBOX - R380
37-14 REPAIRS
24.Remove clevis pin and 'C' washer securing low
ratio selector cable to lever and release cable
from lever housing.
25.Remove 2 cable ties securing cable to fuel
pipes.
26.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
27.Remove banjo bolts securing breather pipes
and discard sealing washers. 28.Remove bolt securing breather pipe 'P' clip and
release breather pipes.
29. If fitted: Disconnect 2 Lucars from differential
lock switch, release and disconnect transfer
box neutral sensor multiplug.
30. If fitted: Release harness from 2 retaining
clips.
31.Position container to catch oil spillage
32.Remove 3 bolts securing oil cooling pipe
housing to gearbox, release housing and
discard 'O' rings.
33.Using a second jack support the weight of the
engine.

MANUAL GEARBOX - R380
REPAIRS 37-15
34.Remove 14 bolts securing gearbox to engine.
35.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.Raise gear gearbox on jack and align to clutch
and engine.
3.Fit bolts securing gearbox to engine and
tighten to 45 Nm (33 lbf.ft).
4.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
5.Position coolant pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
6. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to neutral sensor.
7.Position breather pipes and secure 'P' clip with
bolt.
8.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
9.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
10.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
11.Secure cable to fuel pipes with new cable ties.
12.Raise gearbox, ensuring gear change lever is
located in grommet.
13.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft). 14.Fit nuts to mountings and tighten to 48 Nm (37
lbf.ft).
15.Remove 3 bolts securing support plate to
gearbox.
16.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
17.Clean handbrake back plate and mating face.
18.Position handbrake back plate, fit bolts and
tighten to 75 Nm (46 lbf.ft).
19.Clean handbrake drum.
20.Fit handbrake drum and tighten retaining
screw.
21.Clean propeller shafts and mating faces.
22.Position propeller shafts, align to marks and
tighten bolts to 47 Nm (35 lbf.ft).
23.Clean exhaust silencer and tail pipe mating
faces.
24.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
25.Position rear cross member, fit bolts and
tighten to 25 Nm (18 lbf.ft).
26.Refill gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
27.Refill transfer gearbox oil.

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

+ MANIFOLDS AND EXHAUST
SYSTEMS - V8, REPAIRS, Front pipe.
29.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
30.Fit gear lever trim and gear change knob.
31.Connect battery earth lead.
32. Fit battery cover and cooling fan cover and
secure fixings.

MANUAL GEARBOX - R380
37-18 REPAIRS
23.Remove clevis pin and 'C' washer securing low
ratio selector cable to lever and release cable
from lever housing.
24.Remove 2 cable ties securing cable to fuel
pipes.
25.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
26.Remove banjo bolts securing breather pipes
and discard sealing washers.
27.Remove bolt securing breather pipe 'P' clip and
release breather pipes. 28. If fitted: Disconnect 2 Lucars from differential
lock switch, release and disconnect transfer
box neutral sensor multiplug. Release harness
from 2 retaining clips.
29.Position container to catch oil spillage
30.Remove 2 bolts securing oil cooling pipe
housing to gearbox, release housing and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
31.Using a second jack support the weight of the
engine.

MANUAL GEARBOX - R380
REPAIRS 37-19
32.Remove 8 bolts securing gearbox to engine.
33.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.With assistance raise gearbox on jack and
align to clutch and engine.
3.Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4.Clean oil cooling pipe housing mating faces.
5.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6.Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8.Position breather pipes and secure 'P' clip with
bolt.
9.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12.Secure cable to fuel pipes with new cable ties. 13.Raise gearbox, ensuring gear change lever is
located in grommet.
14.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15.Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16.Remove 3 bolts securing support plate to
gearbox.
17.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18.Clean handbrake back plate and mating face.
19.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20.Clean handbrake drum.
21.Fit handbrake drum and tighten retaining
screw.
22.Fit front propeller shaft.

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

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
24.Clean exhaust silencer and tail pipe mating
faces.
25.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26.Fit exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
27.Refit starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
28.Refill gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
29.Refill transfer gearbox with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31.Fit gear lever trim and gear change knob.
32.Connect battery earth lead.
33.Fit cooling fan cowl and battery cover and
secure fixings.

TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-13
Description
General
The LT 230SE transfer box is mounted at the rear of the gearbox and transmits drive via high or low reduction ratios
to the front and rear axles via the propeller shafts. The high/low ratios are 1.211:1 and 3.32:1 respectively.
Transfer boxes fitted to this model have the prefixes 41D and 42D to the unit serial number. Prefix 41D denotes that
the unit is not fitted with interlock whilst 42D denotes that interlock is fitted.
Vehicles up to 03 model year – Whilst similar to LT230Q transfer boxes fitted to other models, the LT230SE transfer
box has certain engineering modifications incorporated which are as follows:
lUprated torque capacity
lModified front and rear output and cross shaft housings
lIntermediate gear bearing pre-load now controlled by a selective, non-collapsible spacer
lSpeedometer drive and driven gears not fitted for this application
lModified high/low sleeve
lModified front output flange and mud shield
lDifferential lock fitted to certain vehicles, but no longer driver operated
lFixed setting of differential lock warning lamp switch on vehicles fitted with differential lock
Vehicles from 03 model year – The LT230SE transfer box is as described above for vehicles up to 03 model year
with the following modifications:
The following items are introduced on vehicles from 03 model year
lRibs added to main casing to reduce operating noise
lBearing retaining nut on the differential carrier has patchlock added to the threads
lInterlock solenoid moved from main casing to selector lever assembly
lIntermediate gears modified with machined internal shoulder and bearing circlips deleted
The following items are introduced later in the 03 model year build programme and therefore may not appear on all
03 model year vehicles
lDriver operated differential lock (if fitted)
lHigh/Low selector shaft fitted with spring assist
lExisting differential lock switch replaced by new design switch.
lNew secondary differential lock switch installed in the front output housing
Construction
The transfer box comprises three main assemblies; the main casing, the front output housing and the rear output
housing. Both output housings and all cover plates are sealed to the main casing by sealant; mud and water ingress
being prevented by mud shields located on the output flanges.
Main casing
The main casing carries the mainshaft input gear, the intermediate gears and the differential, together with the high/
low range gears, selector shaft and fork. The front and rear output housings are bolted to either side of the main
casing.
Transmission neutral sensor
A transmission neutral sensor is fitted on automatic gearbox vehicles for North America and Japan. The sensor is
connected to the BCU and is normally in the open position. The sensor provides an earth path for the BCU which then
interprets the signal and activates an audible warning generated by the IDM if neutral is selected on the transfer box
when the ignition is on.

TRANSFER BOX - LT230SE
41-28 REPAIRS
11.Remove 2 cable ties securing cable to fuel
pipes.
12.Disconnect 2 Lucars from oil temperature
sensor and disconnect reverse lamp switch
multiplug.
13.Remove banjo bolt securing breather pipe and
discard washers.
14. If fitted - Disconnect 2 Lucars from differential
lock switch.
15.Release and disconnect transfer box neutral
switch multiplug. 16.Remove 4 bolts from transfer box bottom plate,
position support plate LRT-99-010 to transfer
box and tighten bolts.
17.Position gearbox support jack and secure
support plate to jack using 4 bolts.
18.Remove 3 bolts securing transfer box to
gearbox.
19.Fit 3 guide studs LRT-41-009 through transfer
box bolt holes to support it during removal.
20.Remove 2 bolts and nut securing transfer box
to gearbox case. If securing stud is removed
during this operation, it must be discarded
and a new stud fitted.
21.Position a jack to support gearbox and engine.