Discovery II (LT) V8-4.0L (2002)
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8. Align selector shaft pin with slot in centre plate and using wooden blocks and hide mallet, release centre plate and collect lower detent ball and
spring.
9. Press out reverse idler shaft using a suitable press.
10. Remove idler gear, needle roller bearing and spacer.
Reassembly
1. Clean centre plate and reverse gear components.
2. Lubricate gearbox components with clean gear oil.
3. Position idler gear, bearing and spacer to idler shaft.
4. Using a suitable press fit idler shaft to centre plate.
5. Using feeler gauges, check clearance between reverse idler and shaft flange; fit a thicker or thinner spacer if necessary in order to achieve correct
clearance:
^
New clearance : 0.04 - 0.38 mm (0.002 - 0.015 in)
^
Service limit : 0.38 mm (0.015 in)
6. Apply sealant, Part No. STC 3254 to gearbox casing.
7. Fit lower spring and detent ball into centre plate, retain using a dummy shaft.
8. Align selector shaft pin with slot in centre plate.
9. Fit centre plate and fit 2 off 8x35 mm slave bolts to retain centre plate in position on gearbox case; recover dummy shaft.
10. Fit filter to gearbox case.
11. Fit interlock spool to selector shaft.
12. Using new 'O,ring, fit spool retainer and tighten bolts to 8 Nm (6 ft. lbs.).
13. Clean threads of detent plug.
14. Apply Loctite 290 to threads of detent plug, fit upper detent ball and spring.
15. Fit detent plug and tighten to 25 Nm (18 ft. lbs.).
16. Position reverse gear to layshaft.
17. Position reverse gear complete with bearing, collar and selective spacer to output shaft.
18. Fit 5th / reverse gear synchronizer.
