Discovery 2 TD5 gearbox oil change

[martintd5]

How to empty and then fill the gearbox?
Special tools needed?
I hear that they is a way using bottles and tubes to fill the gearbox, I did see a online guide , but now cannot find it.
any clues anyone?:confused:

[seekingserenity]

I recently changed the gearbox oil in Bvudzi's truck.

Jack it up, get it level and axle-stand it (spirit level on running board is a good indicator). All you need are an appropriate-sized allenkey for the drain plug and filler cap, and spanner to fit the bolts around the sump.

Drain oil.

Loosen the bolts all round, bit at a time (some of them are hell to get at...), drop the sump. This should leave you with the sieve and a plastic bit with a pipe on it (oil intake). Remove these carefully (I think there's a bolt on the sieve).

Check the gasket around the sump - ours was in good nick and didn't need replacing. We cleaned the sieve thoroughly with acetone, rinse and swirl type, and removed a lot of rubbish. Rinse it from both ends - top and bottom. Wash with the dishes - normal dish soap and hot water (carefully to avoid domestic battles...). Allow to dry thoroughly so there's no water left in it anywhere. You may want to give the sump a clean while you're at it. There could be pieces of steel on the magnet at the bottom of the sump. There could also just be general dirt and grime and sticky gunk. It comes out amazing after a cycle in a dishwasher.

Replace the o-rings.

Re-assemble starting with plastic pipe thing and sieve, position the sump, bolt it in a bit at a time, going around to tighten one by one slowly to keep the sump level and fitting on it's holder.

Don't forget to replace the sump plug... :D

Start topping up with oil - I used an oil can with pump action, but that kinda kills the hands after half an hour.

Once the oil runs out the filler, switch the engine on, let it warm up, work it through the gears. It may grate when you put it back into park - don't panic. Keep working gears while the engine idles - and preferably have someone down there topping up the oil while you do until it once again comes out the filler - it should be full. Warn them about hot exhausts and pipes and stuff - can get pretty heated down there after a few minutes and filling up the sump is done at an odd angle if you're lying flat on your back.

(The oil pump only works when the engine's running)

There's a lot of oil that stays in the torque convertor when you change the oil. Even though the gearbox has a 9.75 litre capacity, you'll probably use about 5 litres filling it up again.

Once you've run the truck for a few days, check the oil levels again and top up as needed.

There you go - easy as that!