Workshop Manuals Factory service & repair Land Rover
01 Introduction02 General information03 General data04 Identification numbers05 Torque wrench settings06 Lifting and towing07 Capacities, fluids and lubricants08 Maintenance09 Engine - Td510 Engine - V811 Emission control - Td512 Emission control - V813 Engine management system - Td514 Engine management system - V815 Fuel delivery system - Td516 Fuel delivery system - V817 Cooling system - Td518 Cooling system - V819 Manifolds and exhaust systems - Td520 Manifolds and exhaust systems - V821 Clutch - Td522 Clutch - V823 Manual gearbox - R38024 Transfer box - LT230SE25 Automatic gearbox - ZF4HP22/2426 Propeller shafts27 Rear axle28 Front axle29 Steering30 Front suspension31 Rear suspension32 Brakes33 Restraint systems34 Doors35 Exterior fittings36 Interior trim components37 Screens38 Seats39 Sunroof40 Chassis and body dimensions41 Panel repairs42 Body sealing materials43 Corrosion prevention and sealing44 Painting45 Heating and ventilation46 Air conditioning47 Wipers and washers48 Charging and starting49 Lighting50 Body control unit51 Alarm system and horn52 Windows53 In car entertainment54 Harnesses55 Driving aids56 Navigation system57 Instruments
Land Rover Discovery II (UK)23 · Manual gearbox - R380
23 · Transmission

Reassembly

Make
Land Rover
Model
Discovery II (UK)
Section
Overhaul › Reassembly
Manual gearbox - R380Reassembly
  1. Remove 2 bolts securing spool retainer to gearbox case. Remove retainer, remove and discard 'O' ring - if fitted.
  2. Remove interlock spool from selector shaft.
Remove interlock spool from selector shaft.
  1. Remove filter from gearbox case.
Remove filter from gearbox case.
  1. 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.
Align selector shaft pin with slot in centre plate and using wooden blocks and hide mallet
  1. Press out reverse idler shaft using a suitable press.
  2. 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: l New clearance = 0.04 - 0.38 mm (0.002 - 0.015 in) l Service 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.

Parts & tools for this job For Land Rover Discovery

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