Discovery II
MANUAL GEARBOX - R380
OVERHAUL
37-31
17. Invert output shaft in vise and fit 3rd gear,
bearing, baulk rings, 3rd / 4th synchroniser and
spacer.
18. Remove output shaft from vice.
19. Using tool LRT-99-002 and a suitable mandrel,
press pilot bearing onto output shaft.
20. Check end float of 3rd gear between gear and
flange on output shaft:
l
New = 0.11 - 0.21 mm (0.004 - 0.0083 in)
l
Service 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:
l
New = 0.00 to 0.05 mm (0.0 to - 0.002 in)
l
Service 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.
OVERHAUL, Fork - set - selector shaft.
38. Fit gearbox front cover.
