2002 LAND ROVER DISCOVERY service

MANUAL GEARBOX - R380
37-30 OVERHAUL
5.Using tool LRT-99-002 and support bars under
3rd gear, press off output shaft pilot bearing.
6.Remove spacer, 3rd / 4th gear synchroniser
hub, synchromesh baulk rings, 3rd gear and
needle roller bearing.
7.Remove output shaft.
Reassembly
1.Clean output shaft, synchroniser hubs, gears
and bearings.
2.Position output shaft in protected vice jaws,
output end upwards.
3.Fit 2nd gear bearing, 2nd gear and
synchromesh baulk rings onto output shaft.
4.Position 1st / 2nd synchroniser hub onto output
shaft. Ensure that baulk rings are correctly
located in hub.
5.Position 1st gear synchromesh baulk rings,
needle roller bearing, 1st gear and bearing
collar onto output shaft. Ensure baulk rings are
correctly located in hub.
6.Remove output shaft from vice. 7.Using tool LRT-37-001, LRT-37-044 and
LRT-99-002, press taper bearing onto output
shaft.
8.Check end float of 1st gear using a feeler gauge
between gear and collar flange:
lNew = 0.05 - 0.20 mm (0.002 - 0.008 in)
lService limit = 0.327 mm (0.012 in)
9.Check end float of 2nd gear using a feeler
gauge between gear and output shaft flange:
lNew = 0.04 - 0.21 mm (0.0016 - 0.0083 in)
lService limit = 0.337 mm (0.013 in)

MANUAL GEARBOX - R380
OVERHAUL 37-31
10.Invert output shaft in vice and fit 3rd gear,
bearing, baulk rings, 3rd / 4th synchroniser and
spacer.
11.Remove output shaft from vice.
12.Using tool LRT-99-002 and a suitable mandrel
press pilot bearing onto output shaft.
13. 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)
14.Fit gearbox selector fork set.

+ MANUAL GEARBOX - R380,
OVERHAUL, Fork - set - selector shaft.
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).

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.

AUTOMATIC GEARBOX - ZF4HP22 - 24
44-16 DESCRIPTION AND OPERATION
Warning lamps
Warning lamps and selector lever position indication
1Transmission temperature warning lamp (red)
2Gear selector lever position indication
3Sport mode warning lamp (green)
4Manual mode warning lamp (green)
Illumination for each warning lamp is provided by a non serviceable LED.

PROPELLER SHAFTS
47-2 DESCRIPTION AND OPERATION
Description
General
Front and rear propeller shafts transmit the drive from the transfer box to the axles.
On vehicles from 03 model year fitted with the 4.6l V8 engine and 4HP24 transmission, the front propeller shaft is 15
mm (0.6 in) longer and the rear propeller shaft is 15mm (0.6 in) shorter than those used on vehicles with the 4.0l V8
and Td5 engines. This is to accomodate an increase in length of the 4HP24 transmission.
Front propeller shaft
1Hookes joint
2Grease nipple
3Universal joint
4Gaiter/Sliding spline joint
5Lubrication point
The front propeller shaft consists of a tube with a universal joint and a sliding spline joint at the front end, and a
Hookes joint at the rear end. The universal joint is bolted to the pinion flange of the front axle differential. The Hookes
joint is bolted to the front output shaft of the transfer box.
The Hookes joint is lubricated during manufacture and sealed for life. A grease nipple is installed in the universal joint
to lubricate the serviceable, sealed needle bearings of the joint. The sliding spline joint is sealed with a gaiter and
lubricated through a lubrication point on the tube. Because of the proximity of a chassis crossmember to the front
propeller shaft, the lubrication point is normally sealed with a grub screw. During maintenance, the grub screw is
temporarily replaced by a slave grease nipple to lubricate the sliding spline joint.

PROPELLER SHAFTS
DESCRIPTION AND OPERATION 47-3
Rear propeller shaft
1Flexible coupling
2Grease nipple
3Universal joint
4Gaiter/Sliding spline joint
5Grease nipple
The rear propeller shaft consists of a tube with a universal joint and a sliding spline joint at the front end, and a flexible
coupling bolted to the rear end. The universal joint is bolted to the rear output shaft of the transfer box. The flexible
coupling is bolted to the pinion flange of the rear axle differential.
A grease nipple is installed in the universal joint for lubrication of the serviceable, sealed needle bearings in the joint.
The sliding spline joint is sealed with a gaiter and lubricated through a grease nipple in the tube.

STEERING
DESCRIPTION AND OPERATION 57-7
Reservoir
1Filler cap
2Reservoir body (dual PAS/ACE shown )
3Filter
4Supply connection
5Return connection
The fluid reservoir is made of moulded plastic and is located on LH side of the engine compartment, on a bracket
which is attached to the inner wing. Dependent on the vehicles specification the reservoir may be a dual PAS/ACE,
or PAS only reservoir. Both types of reservoir are similar to each other the dual PAS/ACE reservoir has two chambers,
the PAS only reservoir has one chamber of a larger capacity. On both types of reservoir the PAS chamber has its own
filler cap and is identified by lettering on the reservoir body.
A filter of fine polyester mesh is moulded into the base of the chamber. The filter removes particulate matter from the
fluid before it is drawn into the supply connection and is non-serviceable. Upper and lower level marks are moulded
into the reservoir body, the reservoir is fitted with filler cap, a seal in the cap prevents leakage. The filler cap is pushed
onto a latch and turned through 90
° to lock. A breather hole is incorporated in the cap to allow venting of air due to
fluid level changes during operation. The breather hole also allows air that may be in the fluid to separate out and vent
to atmosphere.
The reservoir holds hydraulic fluid and allows for expansion and contraction of the fluid due to temperature variations.
With the reservoir correctly filled the inlet to the PAS pump will be kept covered at normal operational attitudes. The
fluid flowing to the reservoir is cooled by convection from the pipe surfaces, the fluid held in the reservoir also allows
convection from the sides of the reservoir to take place. The total capacity of the reservoir with PAS only is 1000 cc
(0.264 US gallons), for vehicles fitted with PAS and ACE the total capacity of the reservoir is 500 cc (0.132 US
gallons).

STEERING
57-44 REPAIRS
14.Position steering column assembly in a vice.
15.Remove 2 screws and remove ignition switch.
16.Remove cable tie and remove multiplug from
ignition switch.
17.Centre punch or drill out steering lock shear
bolts.
18.Remove steering lock
Refit
1.Position lock to steering column assembly and
fit shear bolts. Do not tighten shear bolts at this
stage.
2.Insert starter key, check operation of steering
lock and that key turns freely.
3.Tighten shear bolts fully and shear heads off.
4.Position ignition switch to column, fit and
tighten screws.
5.Position multiplug to switch and secure with
new cable tie.
6.Fit rubber boot to column.
7.Remove column from vice.
8.Position steering to fascia rail fit nuts and
tighten to 22 Nm (16 lbf.ft).
9.Secure harness to column clip.
10.Position rubber grommet.
11.Close access panel and secure turn buckles.
12.Connect ignition switch multiplugs.
13.Position column switch and tighten clamp
screw.
14.Connect column switch multiplugs.
15.Position passive coil, connect multiplug and
illumination bulb.
16.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
17.Fit rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
18.Close fascia lower access panel.
19.Fit steering column intermediate shaft.

+ STEERING, REPAIRS, Shaft -
intermediate and universal joint - steering
column.
Shaft - intermediate and universal joint -
steering column
$% 57.40.22
The intermediate shaft has a red indicator clip
fitted which must be inspected at service, and
after the vehicle has been subject to an impact.
If the clip is not present or is not fully seated
against the clamp plate, a new assembly must be
fitted.
Remove
1. LHD diesel: Loosen 2 clips securing
intercooler to turbocharger hose. Place hose
aside.