2002 LAND ROVER DISCOVERY maintenance

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
37-16 REPAIRS
Gearbox - Diesel
$% 37.20.02.99
Remove
1.Release turn buckles and remove battery cover
and cooling fan cowl.
2.Disconnect battery earth lead.
3.Remove gear lever knob and gear lever trim.
4.Remove clamp bolt and remove gear lever
extension.
5.Apply a little lubricant to gear lever to aid
removal through grommet.
6.Remove exhaust front pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.7.Remove starter motor.

+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
8.Drain gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
9.Drain transfer gearbox oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove 3 nuts securing intermediate silencer
to tail pipe.
11.Release silencer from mounting rubbers,
remove silencer and discard gasket.
12.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.

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.

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.

TRANSFER BOX - LT230SE
REPAIRS 41-23
REPAIRS
Bottom cover - transfer box
$% 41.20.06
Remove
1.Raise vehicle on ramp.
2.Drain transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
3.Remove 8 bolts securing cross member to
chassis and remove cross member.
4.Remove 10 bolts securing bottom cover to
transfer box and remove cover. Refit
1.Clean bottom plate and mating face on transfer
box.
2.Clean bolt threads.
3.Apply sealant, Part No. STC 3254 to bottom
plate sealing face.
4.Apply Loctite 290 to bolt threads.
5.Position bottom plate and tighten bolts to 25
Nm (18 lbf.ft).
6.Position cross member to chassis and tighten
bolts to 26 Nm (19 lbf.ft).
7.Fill transfer box with oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
8.Lower vehicle on ramp.

TRANSFER BOX - LT230SE
41-24 REPAIRS
Transfer box - Diesel
$% 41.20.25.99
Remove
1.Remove front exhaust pipe.

+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
2.Raise vehicle on ramp.
3.Drain transfer box oil.

+ MAINTENANCE, PROCEDURES,
Transfer box.
4.Remove 3 nuts securing intermediate silencer
to tail pipe.
5.Release silencer from mounting rubbers.
6.Remove silencer and discard gasket.
7.Remove front propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
8.Remove rear propeller shaft.

+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.9.Remove handbrake drum retaining screw and
remove drum.
10.Remove 4 bolts from handbrake back plate,
release back plate and tie aside.
11.Remove clevis pin securing high/low ratio
selector cable to selector lever, remove 'C' clip
and release outer cable from abutment bracket.

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.