Discovery 2. Manual - part 121

MANUAL GEARBOX - R380

OVERHAUL

37-41

Pump - gearbox oil 

$% 37.12.47 

Disassembly

1. Remove gearbox extension.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

2. Remove 3 Torx screws, remove oil pump and 

discard 'O' ring. 

Reassembly

1. Clean oil pump recess in extension housing, 

ensure screw holes are  clean and dry.

2. Lubricate oil pump recess in housing with 

gearbox oil.

3. Lubricate a new 'O' ring with gearbox oil and fit 

to oil pump.

4. Locate oil pump in extension housing with word 

'TOP'  towards top of housing.

5. Align fixing screw holes and tap pump lightly 

around edges until  pump is fully in housing.  Do 
not pull pump into housing  by tightening 
screws.

6. Fit  Torx screws and tighten to 6 Nm (4.5 lbf.ft).
7. Fit gearbox extension.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

Filter - gearbox oil  

$% 37.12.38 

Disassembly

1. Remove gearbox extension.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

2. Remove oil filter from gearbox. 

Reassembly

1. Clean filter recess in gearbox. 
2. Fit filter. 
3. Fit gearbox extension.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380

37-42

OVERHAUL

Gear - 5th gear set  

$% 37.20.36 

Disassembly

1. Remove 5th gear - layshaft.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, 5th gear - layshaft.

2. Using tool  LRT-37-001/2,  LRT-37-009 and  

LRT-37-010, remove output shaft support 
bearing track.

3. Remove 5th gear and baulk ring from output 

shaft. 

Reassembly

1. Clean gears and shafts. 
2. Position 5th gear and baulk ring to output shaft. 

3. Using tool  LRT-37-015 and  LRT-37-021, fit 

support bearing track to output shaft. 

4. Fit 5th gear - layshaft.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, 5th gear - layshaft.

MANUAL GEARBOX - R380

OVERHAUL

37-43

Synchronizer assembly - 5th/reverse  

$% 37.20.38 

Disassembly

1. Remove gearbox rear extension. 

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

2. Remove 5th gear set. 

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Gear - 5th gear set.

3. Remove split needle roller bearing from  output 

shaft. 

4. Remove and discard Allen screw and  remove 

gear change yoke. 

5. Remove and discard circlip securing  5th/

reverse synchronizer hub to output  shaft. 

6. Remove synchronizer hub and selector  fork 

assembly. 

Reassembly

1. Clean gears, shafts, bearings and  selector 

fork. 

2. Position selector fork to synchronizer, fit 

assembly to output shaft and selector  shaft. Fit 
new hub retaining circlip.The fit of the circlip 
is controlled by the selective washer behind 
the reverse  gear bearing collar on the 
output shaft. 

3. Adjust to give a reverse gear end-float of 

0.005 - 0.055mm (0.0002 - 0.0021in).

4. Apply sealant, Part No. STC 50552 to threads 

of new gear change  lever yoke Allen screw.

5. Position  gear change lever yoke and tighten 

Allen screw  to 25 Nm (18 lbf.ft). 

6. Position split needle roller bearing to output 

shaft. 

7. Fit 5th gear set. 

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Gear - 5th gear set.

8. Fit gearbox rear extension.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380

37-44

OVERHAUL

5th gear - layshaft  

$% 37.20.43 

Disassembly

1. Remove gearbox extension.

 

 + 

 MANUAL GEARBOX - R380, 

OVERHAUL, Extension - gearbox rear.

2. Using a suitable two legged puller and  remove 

5th gear layshaft support bearing  track from 
end of layshaft. 

3. Release staking from 5th gear retaining  nut.  

4. Using tool LRT-37-023 to hold 5th  gear, 

remove and discard stake nut.   

5. Remove retaining ring and split collars  

securing 5th gear to output shaft.