2002 LAND ROVER DISCOVERY oil

MANUAL GEARBOX - R380
REPAIRS 37-21
Seal - input shaft
$% 37.23.06
Remove
1.Remove gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
4.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 5.Remove 6 bolts securing bell housing and
remove bell housing.
6.Remove and discard 6 bolts securing oil seal
housing and remove housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing.

MANUAL GEARBOX - R380
37-22 REPAIRS
Refit
1.Using a suitable solvent clean seal housing
mating faces.
2.Clean seal recess, bearings and bearing races.
3.Lubricate new oil seal and fit using a suitable
mandrel into housing.
4.Fit input shaft front bearing track using a press
and suitable mandrel.
5.Apply sealant, Part No. STC 4404 to seal
housing.
6.Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7.Clean bell housing mating faces, dowels and
dowel holes.
8.Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9.Clean release bearing sleeve mating faces,
dowel and dowel holes.
10.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11.Examine clutch release fork pivot points for
wear and replace as required.
12.Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13.Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14.Clean release bearing and bearing sleeve
mating faces.
15.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16.Fit release bearing and secure with retaining
peg.
17.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Cooler - oil - gearbox - Diesel
$% 37.24.02
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release ring and
disconnect both fluid hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.

MANUAL GEARBOX - R380
REPAIRS 37-23
5.Release oil cooler from location on radiator,
and remove the oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Fit oil cooler to radiator and secure with screw.
2.Ensure connections are clean and secure
hoses to cooler.
3.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
4.Top up gearbox oil level.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
Cooler - oil - gearbox - V8
$% 37.24.02
Remove
1. If fitted: Remove engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.
5.Release oil cooler from its location on radiator.

MANUAL GEARBOX - R380
37-24 REPAIRS
6.Move radiator towards engine sufficiently only
to release gearbox oil cooler from radiator.
7.Remove gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Fit gearbox oil cooler to radiator, engage in
location and secure with screw.
2.Ensure connections are clean and secure
hoses to cooler.
3. If fitted: Fit engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
4.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
Switch - Reverse light
$% 37.27.01
Remove
1.Raise vehicle on ramp.
2.Disconnect reverse lamp switch multiplug.
3.Remove switch and collect sealing washer.
Refit
1.Clean switch and mating face on gearbox.
2.Using a new sealing washer, fit the reverse light
switch and tighten to 24 Nm (17 lbf.ft).
3.Connect switch multiplug.
4.Lower vehicle.

MANUAL GEARBOX - R380
OVERHAUL 37-25
OVERHAUL
Shaft - output
$% 37.20.25
Disassembly
1.Remove gearbox selector fork - set

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
2.Remove gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.
3.Remove and discard oil seal and bearing tracks
from front cover.
4.Remove and discard bearing tracks from centre
plate, collect selective shims. 5.Using tool LRT-99-002 and support bars under
1st gear, press output shaft bearing from output
shaft.
6.Remove 1st gear, bearing collar, needle roller
bearing and synchromesh rings.
7.Noting its fitted position, remove 1st / 2nd gear
synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.

MANUAL GEARBOX - R380
OVERHAUL 37-29
20.Check end float of 3rd gear between gear and
flange on output shaft:
lNew = 0.11 - 0.21 mm (0.004 - 0.0083 in)
lService limit = 0.337 mm (0.013 in)
21.Check output shaft and layshaft end float as
follows.
22.The end float setting for both shafts is:
lNew = 0.00 to 0.05 mm (0.0 to - 0.002 in)
lService limit = 0.05 mm (0.002 in)
23.Fit front cover to gearbox case without the oil
seal and tighten bolts by diagonal selection to
25 Nm (18 lbf.ft).
24.Position in vice with front cover facing
downwards.
25.Fit input shaft to gearbox case less 4th gear
baulk ring.
26.Fit output shaft assembly to input shaft.
27.Fit output shaft bearing track and shim to centre
plate.
28.Fit centre plate to gearbox case and secure
using 8 slave bolts.
29.Rotate output shaft to settle bearings.
30.Fit a suitably large ball bearing into end of
output shaft.
31.Position a suitable DTI and zero probe on ball
bearing.
32.Lift output shaft and note DTI reading.
33.If reading is incorrect, dismantle and fit shim to
give correct end float.
34.Repeat above procedure.
35.Repeat procedure for layshaft end float.
36.Remove and discard 6 bolts and remove
gearbox front cover.
37.Fit gearbox selector fork - set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
38.Fit gearbox front cover.

+ MANUAL GEARBOX - R380,
OVERHAUL, Cover - front.
Synchroniser - gearbox - set
$% 37.20.07
Disassembly
1.Remove gearbox selector fork set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
2.Using tool LRT-99-002 and support bars
under 1st gear, press output shaft bearing from
output shaft.
3.Remove 1st gear, bearing collar, needle roller
bearing and synchromesh rings.
4.Noting its fitted position, remove 1st / 2nd gear
synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.

MANUAL GEARBOX - R380
37-32 OVERHAUL
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.
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.

MANUAL GEARBOX - R380
OVERHAUL 37-33
5.Using tool LRT-37-004, and LRT-99-004,
remove pilot bearing track from input shaft.
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.