R380 gearbox mainshaft spline wear

R380 GEARBOX MAINSHAFT SPLINE WEAR

Model

Discovery All Derivatives Discovery All Derivatives Defender All Derivatives

Affected vehicles

178205 Onwards 506525 Onwards 976480 Onwards

Date

1996-01-31

Reference

31/01/96

Bulletin text

Transfer Box Input Gear - New Part Introduction

MODEL

Discovery All Derivatives Discovery All Derivatives Defender All Derivatives

DETAIL

From LT 230 transfer box numbers 28D 460996 F (Discovery) and 22D 461124 F (Defender)all factory built transfer boxes have a revised design of input gear, featuring lengthened splines and cross drilled oil feed holes. This modification eliminates the requirement for an oil feed disc (ref bulletin A/B/D 415) and overcomes input gear/mainshaft spline fretting/wear.

Note: Coincident with this change the transfer box identification number has been raised to Suffix ‘F’. Note: To aid assembly of gearbox and transfer box the mainshaft output spline can be lubricated with the appropriate transfer box oil. Grease should not be used as the cross drilled holes may become filled with grease preventing lubrication.

This bulletin supercedes 41/06/95/EN issue 2 as the information in the parts section has changed

ACTION REQUIRED

Information only: The new parts are fully interchangeable in all LT 230 applications and should be used in preference to the old parts in the event of a repair being made. Note: Do not use in conjunction with an oil feed disc.

PARTS INFORMATION

FTC 5087 replaces FTC 4188 and FTC 4878 (ratio1:1.214 (28 teeth) FTC 5089 replaces FRC 8917 (ratio1:1.410 (26 teeth)

FTC 5090 replaces FTC 3981 Coupling shaft

PROCEDURE

Refer to the workshop manual section 41 for strip and re-assembly of the transfer box.

When coupled to a ZF Automatic gearbox a new coupling shaft is required with extended splines. This is factory fit for all Discovery Automatics from LT 230 transfer box suffix ‘F’ introduction.

Issue 3 31/01/96 41/06/95/EN

AFFECTED VEHICLES

LP LJ 178205 Onwards LJ 506525 Onwards LD 976480 Onwards

WARRANTY

Normal warranty policy and procedures apply

COMP. CODE

3H2J

SRO

Refer to individual service repair operation numbers.