300Tdi Discovery
R380
1
REPAIR
R380 MANUAL GEARBOX
Service repair no - 37.20.02
Remove
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer’s instructions to ensure safe and
effective use of equipment.
1. Install vehicle on a ramp [hoist].
2. Disconnect battery earth lead.
3. Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
4. Remove sound insulation from top of
transmission tunnel.
5. Remove bolt and remove upper gear lever.
6. Remove screws securing gear selector lever and
high/low selector lever draft excluders.
7. Remove draft excluder clamp rings.
8. Remove handbrake cable clevis pin clip and
clevis pin.
9. Remove ’C’ clip and cable adjuster.
10. Select low range to prevent gear lever fouling
tunnel when removing gearbox.
11. Remove bolt securing gearbox breather pipe clip
to cylinder block.
12. Remove bolts securing fan cowl to radiator.
13. Release fan cowl from radiator and lay over fan
blades.
14. Raise ramp [hoist].
15. Drain oil from main gearbox and transfer
gearbox.
See SECTION 10, Maintenance,
Under Vehicle Maintenance
16. Remove exhaust front pipe(s).
See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
System Complete
17. Release intermediate exhaust pipe(s) from
mountings and tie aside.
18. Remove bolts securing clutch slave cylinder.
19. Release slave cylinder from clutch housing and
collect spacer.
20. Mark propeller shaft drive flange relationships for
reassembly.
21. Disconnect front and rear propeller shafts from
transfer gearbox. Tie shafts aside.
22. Remove clamp and disconnect speedometer
cable from transfer gearbox.
23. Release handbrake cable from transmission
tunnel.
24. Temporarily support transmission in a way which
enables the crossmember to be removed and a
hoist cradle to be fitted.
