2002 LAND ROVER DISCOVERY ECU

MANUAL GEARBOX - R380
37-36 OVERHAUL
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 Loctite 290 to threads of reverse inhibitor
shaft, fit and tighten shaft.
8.Apply Loctite 290 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.
12.Fit new output shaft oil seal using tool LRT-37-
014.

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
OVERHAUL 37-39
Reassembly
1.Clean gears and shafts.
2.Position 5th gear and baulk ring to output shaft.
3.Using tool LRT-37-015 and LRT-37-021, fit
support bearing track to output shaft.
4.Fit 5th gear - layshaft.

+ MANUAL GEARBOX - R380,
OVERHAUL, 5th gear - layshaft.
Synchronizer assembly - 5th/reverse
$% 37.20.38
Disassembly
1.Remove gearbox rear extension.

+ MANUAL GEARBOX - R380,
OVERHAUL, Extension - gearbox rear.
2.Remove 5th gear set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Gear - 5th gear set.
3.Remove split needle roller bearing from output
shaft.
4.Remove and discard Allen screw and remove
gear change yoke.
5.Remove and discard circlip securing 5th/
reverse synchronizer hub to output shaft.
6.Remove synchronizer hub and selector fork
assembly.

MANUAL GEARBOX - R380
OVERHAUL 37-41
5.Remove retaining ring and split collars
securing 5th gear to output shaft.
6.Remove split collar and 5th gear from layshaft. Reassembly
1.Clean gear and layshaft.
2.Position 5th gear and split collar to layshaft
ensuring that bevelled side of collar is towards
5th gear.
3.Position split collars and retaining ring securing
5th gear to output shaft.
4.Position tool LRT-37-023 to hold 5th gear and
tighten new stake nut to 220 Nm (162 lbf.ft) and
stake nut.
5.Apply a small amount of heat and fit support
bearing track to layshaft.
6.Fit gearbox extension.

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

MANUAL GEARBOX - R380
OVERHAUL 37-45
5.Remove 2 bolts securing spool retainer to
gearbox case. Remove retainer, remove and
discard 'O' ring - if fitted.
6.Remove interlock spool from selector shaft.
7.Remove filter from gearbox case.
8.Align selector shaft pin with slot in centre plate
and using wooden blocks and hide mallet,
release centre plate and collect lower detent
ball and spring. 9.Press out reverse idler shaft using a suitable
press.
10.Remove idler gear, needle roller bearing and
spacer.
Reassembly
1.Clean centre plate and reverse gear
components.
2.Lubricate gearbox components with clean gear
oil.
3.Position idler gear, bearing and spacer to idler
shaft.
4.Using a suitable press fit idler shaft to centre
plate.
5.Using feeler gauges, check clearance between
reverse idler and shaft flange; fit a thicker or
thinner spacer if necessary in order to achieve
correct clearance:
lNew clearance = 0.04 - 0.38 mm (0.002 -
0.015 in)
lService limit = 0.38 mm (0.015 in)
6.Apply sealant, Part No. STC 3254 to gearbox
casing.
7.Fit lower spring and detent ball into centre
plate, retain using a dummy shaft.
8.Align selector shaft pin with slot in centre plate.
9.Fit centre plate and fit 2 off 8x35 mm slave bolts
to retain centre plate in position on gearbox
case; recover dummy shaft.

MANUAL GEARBOX - R380
OVERHAUL 37-47
Lever - gear change
$% 37.16.04
Disassembly
1.Remove gear selector housing.

+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
2.Restrain right hand bias spring using a suitable
pair of grips.
3.Remove 2 bolts securing right hand side of bias
spring adjustment plate.
4.Repeat operations for left hand bias spring.
5.Remove bias springs and adjustment plate.6.Remove lower gear lever.
7.Remove and discard Railko bush.
8.Remove and discard oil seal from housing.
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 Loctite 290 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.

MANUAL GEARBOX - R380
OVERHAUL 37-49
Cover - front
$% 37.12.33.01
Disassembly
1.Remove retaining peg and remove release
bearing.
2.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
3.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 4.Remove 6 bolts securing clutch housing and
remove clutch housing.
5.Remove and discard 6 bolts securing oil seal
housing.
6.Remove oil seal housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing, discard seal.

MANUAL GEARBOX - R380
37-50 OVERHAUL
Reassembly
1.Using a suitable solvent cleaner, 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, fit new bolts and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
6.Clean clutch housing mating faces, dowels and
dowel holes.
7.Position clutch housing, fit bolts and tighten to
75 Nm (55 lbf.ft).
8.Clean release bearing sleeve mating faces,
dowel and dowel holes.
9.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
10.Examine clutch release fork pivot points for
wear and replace as required.
11.Apply a smear of Molybdenum disulphide
grease to pivot points and position release fork.
12.Fit retaining clip ensuring it locates over pivot
point washer, fit bolt to release fork and tighten
to 10 Nm (7 lbf.ft).
13.Clean release bearing and bearing sleeve
mating faces.
14.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
15.Fit release bearing and secure with retaining
peg.