Discovery 2. Manual — part 120
MANUAL GEARBOX - R380
OVERHAUL
37-37
Reassembly
1. Clean input shaft and bearing/oil seal recess in
front cover.
2. Lubricate a new input shaft oil seal with
gearbox oil.
3. Fit oil seal using a suitable mandrel.
4. Using a press and a suitable mandrel, fit
bearing outer track in front cover.
5. Using a press and a suitable mandrel, fit pilot
bearing outer track to input shaft.
6. Using tool LRT-37-043, LRT-37–043/2 and
LRT-99-002, fit new taper bearing to input
shaft.
7. Using tool LRT-99-002 and a suitable mandrel,
press new pilot bearing onto output shaft.
8. Position input shaft to gearbox case.
9. With assistance, fit output shaft and layshaft
assembly into gearbox case.
10. Fit reverse idler gear shaft.
OVERHAUL, Shaft - reverse idler.
11. Fit gearbox front cover.
MANUAL GEARBOX - R380
37-38
OVERHAUL
Extension - gearbox rear
$% 37.12.01
Disassembly
1. Remove 4 bolts and remove gear selector
housing.
2. Using tools LRT-37-009, LRT-37-001/2 and
LRT-37-010 , remove output shaft oil seal
collar.
3. Remove bolt securing interlock spool retainer
and discard 'O' ring.
4. Noting fitted position of 2 longest bolts, remove
10 bolts securing extension housing to
gearbox.
5. Remove extension housing from gearbox
centre plate.
MANUAL GEARBOX - R380
OVERHAUL
37-39
6. Fit 2 off 8x35 mm slave bolts to secure centre
plate to gearbox casing.
7. Remove 3 Torx screws, remove oil pump and
discard 'O' ring.
8. Drift out layshaft support bearing.
9. Remove and discard output shaft rear oil seal.
10. Remove oil pick-up pipe.
11. Drift out output shaft support bearing and oil
pick-up ring.
12. Remove reverse inhibitor shaft, cam and
spring.
13. Remove 2 bolts and remove gate plate.
14. Remove reverse light switch and discard
sealing washer.
15. Remove 2 bolts, remove oil cooler by-pass and
discard 'O' rings.
Reassembly
1. Clean extension housing and mating faces.
2. Clean oil cooler by-pass.
3. Using new 'O' rings, fit oil cooler by-pass and
tighten bolts to 15 Nm (11 lbf.ft).
4. Using new sealing washer, fit reverse light
switch and tighten to 24 Nm (17 lbf.ft).
5. Fit reverse inhibitor spring and cam.
6. Clean threads of reverse inhibitor shaft and
gate plate bolts.
7. Apply sealant, Part No. STC 50552 to threads
of reverse inhibitor shaft, fit and tighten shaft.
8. Apply sealant, Part No. STC 50552 to threads
of gate plate bolts.
9. Position gate plate and tighten bolts to 15 Nm
(11 lbf.ft).
10. Fit output shaft support bearing and oil pick-up
ring. Align tag with centre of drain slot.
11. Fit layshaft support bearing.
MANUAL GEARBOX - R380
37-40
OVERHAUL
12. Fit new output shaft oil seal using tool LRT-37-
014.
13. Fit oil pick-up pipe with the off-set uppermost.
14. Lubricate oil pump recess with gearbox oil.
15. Lubricate a new 'O' ring with gearbox oil and fit
to oil pump.
16. Locate oil pump in extension housing with word
'TOP' towards top of housing.
17. Align oil pump fixing screw holes and tap pump
lightly around edges until it is fully in recess.
Do not attempt to pull pump into recess
using fixing screws.
18. Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
19. Remove 2 slave bolts securing centre plate to
gearbox casing.
20. Apply sealant, Part No. STC 4404 to gearbox
casing face.
21. Position extension housing, align oil pump drive
with layshaft.
22. Clean extension housing bolt threads.
23. Apply sealant, Part No. STC 50552 to threads
of extension housing bolts, fit bolts ensuring 2
longest bolts are in their original positions and
tighten by diagonal selection to 25 Nm (18
lbf.ft).
24. Using new 'O' ring, fit interlock spool retainer
and tighten bolt to 8 Nm (6 lbf.ft).
25. Using tool LRT-37-015 and LRT-37-021, fit oil
seal collar.
26. Clean gear selector selector housing and
mating face.
27. Apply sealant, Part No. STC 4404 to gear
selector housing face.
28. Position gear selector housing and tighten
bolts to 25 Nm (18 lbf.ft).
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