300Tdi Discovery
R380
3
REPAIR
Assembling transfer gearbox to main gearbox
45. Clean extension housing and transfer gearbox
mating faces.
46. Ensuring loose upper dowel is fitted, hoist
transfer gearbox into position.
47. Fit and tighten nut and bolts to
34Nm.
48. Connect high/low operating rod, fit and tighten
locknut.
49. Fit link to differential lock lever and secure with 2
clips
50. Align lever to high/low shaft, position washer, fit
bolt and new Nyloc nut. Tighten to
2Nm.
51. Position breather pipes, secure pipe unions
using new sealing washers. Tighten unions to
15Nm.
Fitting transfer gearbox and main gearbox
assembly to engine
52. Position transmission assembly to hoist cradle.
53. Clean bell housing and engine mating faces.
54. Temporarily fit gear lever and select any gear in
main gearbox to facilitate entry of gearbox input
shaft.
55. Position and raise hoist, and fit transmission to
engine whilst keeping wires and pipes clear to
prevent trapping.
56. Fit and tighten nuts securing transmission to
engine.
57. Connect reverse lamp switch connectors and
differential lock switch connectors.
58. Secure breather pipes to harness with clips.
59. Position temporary support.
60. Remove 2 bolts securing lifting cradle to
transmission and remove hoist. Apply Loctite
290 to bolts and refit bolts.
61. Position cross-member, loosely fit nuts and bolts
securing cross-member mountings to
transmission.
62. Raise transmission, align cross-member and
loosely fit nuts and bolts securing cross-member
to chassis.
63. Tighten all securing nuts and bolts. Remove
supporting jack from under sump.
64. Remove temporary support.
65. Fit handbrake cable through transmission tunnel
and secure gaiter.
66. Connect speedometer cable to transfer gearbox.
67. Line up marks and connect front and rear
propeller shafts.
68. Clean spacer, clutch slave cylinder and gearbox
mating faces.
69. Position spacer and slave cylinder, fit bolts.
Tighten to
25Nm.
70. Untie intermediate exhaust pipe(s) and refit
exhaust front pipe(s).
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Exhaust System
Complete
71. Refill main gearbox and transfer gearbox with oil.
See SECTION 10, Maintenance, Under
Vehicle Maintenance
72. Lower ramp [hoist].
73. Fit fan cowl, fit and tighten bolts.
74. Align breather pipe clip to cylinder block, fit and
tighten bolts.
75. Fit handbrake cable adjuster and secure with ’C’
clip.
76. Align cable trunnion to handbrake lever, fit clevis
pin and secure with clip.
77. Check handbrake adjustment.
See SECTION
10, Maintenance, Vehicle Interior
78. Fit upper gear lever, fit and tighten bolt.
79. Fit gear selector lever and high/low selector
lever draft excluders.
80. Position draft excluder clamp rings, fit and
tighten screws.
81. Refit sound insulation.
82. Refit centre console.
See CHASSIS AND
BODY, Repair, Centre Console
83. Connect battery earth lead.
