Discovery II
MANUAL GEARBOX - R380
37-54
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.
