Discovery II
MANUAL GEARBOX - R380
37-22
REPAIRS
Refit
1. Using a suitable solvent 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.
6. Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7. Clean bell housing mating faces, dowels and
dowel holes.
8. Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9. Clean release bearing sleeve mating faces,
dowel and dowel holes.
10. Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11. Examine clutch release fork pivot points for
wear and replace as required.
12. Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13. Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14. Clean release bearing and bearing sleeve
mating faces.
15. Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16. Fit release bearing and secure with retaining
peg.
17. Fit gearbox assembly.