Installing a 2.7L Manual Transmission (Discovery 3)

Installation

1. Place the transmission on a transmission jack.

2.

CAUTION: Make sure the box is not tilted.

CAUTION: Before installing the transmission, make sure the clutch assembly is not damaged.

NOTE: Do not install the transmission completely onto the engine.; a gap of 40 mm must be left.

Install the gearbox with an assistant. Clean the contact surfaces of the parts.

3. Using a transmission jack, rotate the transmission to provide access to the gear shift mechanism.



4. Install the gear shift mechanism onto the gearbox.

5.

CAUTION: Before installing the transmission, make sure the clutch assembly is not damaged.

Align the gearbox with the engine and install the gearbox.



6. NOTE: For clarity, the transfer case housing is shown removed.



Install the 14 gearbox bolts. Tighten the bolts to a torque of 40 Nm.

7. Install the exhaust bypass pipe central support bracket. Tighten the bolts to 25 Nm.

8. Install the wiring harness to its original position on the transmission.

9. Install the left and right exhaust bypass pipe support brackets.

• Align the exhaust bypass pipe assembly support bracket.
• Tighten the bolts evenly to a torque of 25 Nm.

10. Connect the transmission and transfer case ventilation lines.

11. Secure the wiring harness to the gearbox.

• Insert the wiring harness into the clamp.
• Connect the electrical connectors.
• Screw in and tighten the 2 bolts.

12. Raise the transmission jack.

13. Secure the wiring harness to the transfer case.

• Tighten the bolts (tightening torque 25 Nm).
• Insert the wiring harness into the clamp.

14. Connect the transfer case electrical connectors.

15. Connect the gear shift rod.

• Clean the parts.
• Lubricate the parts.
• Install new O-rings.
• Install the clamp.

16. Connect the clutch fluid hose.

• Clean the parts.
• Install a new O-ring.
• Install the clamp.
• Remove the hose clamp.

17. Install the vacuum hose into the clamps.

• Remove the adhesive tape.
• Install the mounting clamps.

18. Secure the fuel filter support bracket. Insert and tighten the two bolts. (tightening torque 10 Nm).

19. Attach the fuel cooler. Insert the bolt and tighten it. (tightening torque 10 Nm).

20. Install the 2 turbocharger support bracket bolts. Tighten the bolts. (tightening torque 25 Nm).

21. Tighten the turbocharger support bracket nut. Tighten the nut to a torque of 25 Nm.



22. Install the exhaust heat shield.

23. Bleed the clutch system.

24. Install the front drive shaft. For more information, refer to Front Drive Shaft - 2.7L Diesel (47.15.02)

25. Remove the transmission jack.

26. Install the lower engine guard. For more information, refer to Engine Guard (76.10.50)

27.

CAUTION: To avoid damage to the hinge or boot, do not allow the drive shaft to hang.

Connect the drive shaft to the transfer case drive flange.

• Remove the mounting tape.
• Tighten the Torx bolts (tightening torque 55 Nm).

28. Tighten the drive shaft center bearing support mounting bolts.

• Align the center bearing support.
• Tighten the 2 drive shaft center bearing support bolts. (tightening torque 30 Nm).

29. Install the fuel tank heat shield.

• Tighten the bolts (tightening torque 6 Nm).
• Tighten the nuts (tightening torque 3 Nm).

30. Lower the car.

31. Install the gear shift lever protective cover.

32. Install the 2 shifter support bracket bolts. Tighten the bolts. (tightening torque 25 Nm).

33. Set the suspension and steering performance optimization switch. For more information, refer to Suspension and steering performance optimization switch. vehicle controllability (86.65.11)

34. Connect the battery ground cable.

(The original text was published on the website: lrman.ru)