Workshop Manuals Factory service & repair Land Rover
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
Diagram
  1. Using tool LRT-99-002 and support bars under 3rd gear, press off output shaft pilot bearing.
Using tool LRT-99-002 and support bars under 3rd gear, press off output shaft pilot bearin
  1. Remove spacer, 3rd / 4th gear synchroniser hub, synchromesh baulk rings, 3rd gear and needle roller bearing.
  2. Remove output shaft.

Reassembly

  1. Clean output shaft, synchroniser hubs, gears and bearings.
  2. Position output shaft in protected vice jaws, output end upwards.
  3. Fit 2nd gear bearing, 2nd gear and synchromesh baulk rings onto output shaft.
  4. Position 1st / 2nd synchroniser hub onto output shaft. Ensure that baulk rings are correctly located in hub.
  5. Position 1st gear synchromesh baulk rings, needle roller bearing, 1st gear and bearing collar onto output shaft. Ensure baulk rings are correctly located in hub.
  6. Remove output shaft from vice.
Reassembly – Remove output shaft from vice.
  1. Using tool LRT-37-001, LRT-37-044 and LRT-99-002, press taper bearing onto output shaft.
Reassembly – Using tool LRT-37-001, LRT-37-044 and LRT-99-002, press taper bearing onto output shaft.
  1. Check end float of 1st gear using a feeler gauge between gear and collar flange: l New = 0.05 - 0.20 mm (0.002 - 0.008 in) l Service limit = 0.327 mm (0.012 in)
Reassembly – Check end float of 1st gear using a feeler gauge between gear and collar flange: l New = 0
  1. Check end float of 2nd gear using a feeler gauge between gear and output shaft flange: l New = 0.04 - 0.21 mm (0.0016 - 0.0083 in) l Service limit = 0.337 mm (0.013 in)

Parts & tools for this job For Land Rover Discovery

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