2002 LAND ROVER DISCOVERY Workshop Manual

CLUTCH - V8
33-2-14 REPAIRS
Master cylinder
$% 33.20.01
CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove fluid and
clean area with water.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Release spring clip securing clutch pedal
clevis pin and remove pin from push rod and
clutch pedal.
3.Position container to catch spillage. Disconnect
hydraulic pipe from clutch master cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.4.Release clip and remove connecting hose from
clutch master cylinder.
5.Remove 2 bolts securing clutch master
cylinder to pedal box and remove clutch master
cylinder.
Refit
1.Clean master cylinder and pedal box mating
faces.
2.Position clutch master cylinder to pedal box, fit
bolts and tighten to 25 Nm (18 lbf.ft).
3.Position clevis pin to push-rod and clutch pedal
and secure with spring clip.
4.Fit connecting hose to brake master cylinder
and tighten clip.
5.Position hydraulic pipe and tighten union to 18
Nm (13 lbf.ft).
6.Bleed clutch.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - V8
REPAIRS 33-2-15
Bearing and lever - clutch release
$% 33.25.12
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 lever.
Remove retaining clip and remove clutch
release lever.
Refit
1.Clean clutch release lever.
2.Examine clutch release lever pivot points for
wear.
3.Apply a smear of Molybdenum disulphide
grease to clutch release lever pivot points.
4.Fit retaining clip, ensuring it locates over clutch
release lever pivot point washer. Fit bolt and
tighten to 8 Nm (6 lbf.ft).
5.Clean release bearing and bearing sleeve
mating faces.
6.Apply a smear of Molybdenum disulphide
grease to release bearing sleeve.
7.Fit release bearing and secure with retaining
peg.
8.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Slave cylinder
$% 33.35.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Position container to catch spillage.
3.Disconnect hydraulic pipe from slave cylinder.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove 2 bolts securing slave cylinder to
gearbox housing and collect heat shield.
5.Withdraw slave cylinder from gearbox housing
and push rod.
Refit
1.Clean ends of pipes, gearbox housing and
slave cylinder mating faces.
2.Lubricate end of push rod with Molybdenum
disulphide grease.
3.Locate slave cylinder to push rod and gearbox
housing.
4.Position heatshield. Fit bolts securing slave
cylinder and tighten to 25 Nm (18 lbf.ft).
5.Connect hydraulic pipe to slave cylinder.
6.Bleed clutch system.

+ CLUTCH - V8, ADJUSTMENTS,
Clutch hydraulic system - bleed.
7.Remove stand(s) and lower vehicle.

CLUTCH - V8
33-2-16 REPAIRS

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-1
MANUAL GEARBOX - R380 DESCRIPTION AND OPERAT ION
R380 gearbox

MANUAL GEARBOX - R380
37-2 DESCRIPTION AND OPERATION
Gearbox casings, gear change and oil
pump

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-3
1Front cover
2Input shaft oil seal
3Oil filler/level plug
4Sealing washer
5Oil drain plug
6Gear case
7Interlock spool retainer, bolt and 'O' ring
8Centre plate
9Locating dowels
10Selector plug, detent balls and spring
11Splash shield and retaining bolt
12Extension housing
13Gate plate and retaining bolt
14Interlock spool retainer, retaining bolt and 'O'
ring – if fitted – extension housing
15Inhibitor cam spring
16Inhibitor cam
17Reverse inhibitor shaft
18Output shaft oil seal
19Oil seal collar
20Oil pump and retaining bolt
21'O' ring
22Reverse lamp switch23Oil by-pass block - UK and European models
24Bolt - oil by-pass block
25'O' ring - oil by-pass block
26Thermostat and housing - non UK and non
European models
27'O' ring - thermostat housing
28Bolt - thermostat housing
29Oil pick-up pipe
30Oil filter
31Oil pick-up ring
32Rubber gaiter
33Cable tie
34Upper gear lever
35Clamp bolt
36Bias springs
37Bolts and washers - bias adjusting plate and
housing
38Bias adjusting plate
39Lower gear lever and ball
40Railko bush
41Oil seal
42Gear change housing

MANUAL GEARBOX - R380
37-4 DESCRIPTION AND OPERATION
Selector shaft and forks, synchromesh
assemblies and gear train

MANUAL GEARBOX - R380
DESCRIPTION AND OPERATION 37-5
13rd/4th gear selector fork
2Interlock spool
31st/2nd gear selector fork
4Selector shaft yoke pins
5Selector shaft
6Reverse/5th gear selector fork
7Selector yoke
8Setscrew
9Input shaft front taper bearing
10Input shaft
11 4th gear synchromesh ring
12Pilot taper bearing
13Spacer
143rd/4th gear synchromesh hub and sleeve
153rd gear synchromesh rings
163rd gear
17Needle roller bearings
18Output shaft
19Roll pin
20Needle bearing
212nd gear
222nd gear synchromesh rings
232nd/1st gear synchromesh hub and sleeve
241st gear synchromesh rings
251st gear
26Needle roller bearing
27Bush
28Output shaft taper bearing 29Selective shim
30Selective washer
31Bush
32Needle roller bearing
33Reverse gear
34Reverse gear synchromesh ring
35Reverse/5th gear synchromesh hub and sleeve
36Circlip
37Needle roller bearings
385th gear synchromesh ring
395th gear
405th gear segments
415th gear segment retaining ring
42Output shaft rear support bearing
43Layshaft support bearing
44Layshaft
45Layshaft support bearing
46Selective shim
47Layshaft reverse gear
48Layshaft 5th gear
49Split collar
505th gear nut
51Layshaft rear support bearing
52Spacer
53Reverse idler gear
54Needle roller bearing
55Reverse idler shaft