Discovery II
MANUAL GEARBOX - R380
REPAIRS
37-19
32. Remove 8 bolts securing gearbox to engine.
33. With assistance, remove gearbox from engine.
Refit
1. Clean gearbox to engine mating faces, dowels
and dowel holes.
2. With assistance raise gearbox on jack and
align to clutch and engine.
3. Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4. Clean oil cooling pipe housing mating faces.
5. Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6. Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8. Position breather pipes and secure 'P' clip with
bolt.
9. Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10. Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11. Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12. Secure cable to fuel pipes with new cable ties.
13. Raise gearbox, ensuring gear change lever is
located in grommet.
14. Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15. Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16. Remove 3 bolts securing support plate to
gearbox.
17. Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18. Clean handbrake back plate and mating face.
19. Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20. Clean handbrake drum.
21. Fit handbrake drum and tighten retaining
screw.
22. Fit front propeller shaft.
23. Fit rear propeller shaft.
24. Clean exhaust silencer and tail pipe mating
faces.
25. Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26. Fit exhaust front pipe.
SYSTEMS - Td5, REPAIRS, Pipe - front.
27. Refit starter motor.
REPAIRS, Starter motor - diesel.
28. Refill gearbox with oil.
29. Refill transfer gearbox with oil.
30. Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31. Fit gear lever trim and gear change knob.
32. Connect battery earth lead.
33. Fit cooling fan cowl and battery cover and
secure fixings.
