Discovery II (LT) V8-4.0L (2002)
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6. Fit layshaft bearing track to front cover.
7. Using tool LRT-99-002 and a suitable mandrel, fit pilot bearing outer track to input shaft.
8. Clean synchronizer hubs, gears and bearings.
9. Position output shaft in protected vice jaws, output end upwards.
10. Fit 2nd gear bearing, 2nd gear and synchromesh baulk rings onto output shaft.
11. Position 1st / 2nd synchronizer hub onto output shaft. Ensure that baulk rings are correctly located in hub.
12. Position 1st gear synchromesh baulk rings, needle roller bearing, 1st gear and bearing collar onto output shaft. Ensure baulk rings are correctly
located in hub.
13. Remove output shaft from vice.
14. Using tool LRT-37-001, LRT-37-044 and LRT-99-002, press taper bearing onto output shaft.
15. Using a feeler gauge, check end float of 1st gear between gear and collar flange:
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New = 0.05 - 0.20 mm (0.002 - 0.008 in)
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Service limit = 0.327 mm (0.012 in)
16. Using a feeler gauge, check end float of 2nd gear between gear and output shaft flange:
^
New 0.04 - 0.21 mm (0.0016 - 0.0083 in)
^
Service limit= 0.337 mm (0.013 in)
17. Invert output shaft in vise and fit 3rd gear, bearing, baulk rings, 3rd / 4th synchronizer and spacer.
18. Remove output shaft from vice.
