Discovery II
MANUAL GEARBOX - R380
37-52
OVERHAUL
Reassembly
1. Clean components.
2. Apply multi-purpose grease to ball and cross
pins.
3. Apply multi-purpose to new Railko bush and fit
to housing ensuring that slots are correctly
aligned.
4. Lubricate a new seal with gearbox oil and fit, lip
side towards housing using a suitable mandrel.
5. Position lower gear lever to selector housing
ensuring cross pins are located in Railko bush.
6. Position bias spring adjustment plate to
selector housing.
7. Clean threads of bias spring adjustment plate
bolts and apply sealant, Part No. STC 50552 to
threads.
8. Fit 2 short bolts to secure front of adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9. Position right hand bias spring to pillar ensuring
longest end of spring is against gear lever.
10. Restrain bias spring using a suitable pair of
grips, ensure shortest end of spring is on
outside edge of bolt hole.
11. Fit longest bolt and washer ensuring end of
bias spring is under washer, tighten bolt to 25
Nm (18 lbf.ft).
12. Repeat above procedures for remaining bias
spring.
13. Fit gear selector housing.
OVERHAUL, Housing - gear selector
mechanism.
14. Adjust gear lever bias springs.
ADJUSTMENTS, Spring - gear lever bias.
Housing - clutch
$% 37.12.07
Disassembly
1. Remove clutch release bearing and operating
lever.
2. Remove 6 bolts and remove clutch housing.
Reassembly
1. Clean clutch housing and gearbox mating face.
2. Position clutch housing and tighten bolts to 75
Nm (55 lbf.ft).
3. Fit clutch operating lever and release bearing.