Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual

R380
GEARBOX
OVERHAUL MANUAL
This Overhaul Manualcontains information
applicable tothe following models:
New Range Rover
Range RoverClassic 1995Models on
Discovery 1995Models on
Defender 1995Models on
Publication PartNo.LRL 0003ENG -2nd Edition
Published byRover Technical Communication
Ó1996 Rover Group Limited  

INTRODUCTIONINTRODUCTION 1
INTRODUCTION How
touse this manual
To assist inthe use ofthis manual thesection titleis
given atthe topand therelevant sub-section is
given atthe bottom ofeach page.
This manual contains procedures foroverhaul ofthe
R380 gearbox onthe bench withtheclutch and,if
applicable, thetransfer boxremoved. Forallother
information regardingAdjustments, Removalofoil
seals, clutch, transfer boxand gearbox unit,consult
the appropriate RepairManual forthe model
concerned.This manual isdivided...

INTRODUCTION 2INTRODUCTION
SPECIFICATION Rover/Land
Roverareconstantly seekingtoimprove
the specification, designandproduction oftheir
vehicles andalterations takeplace accordingly.
While everyefforthasbeen made toensure the
accuracy ofthis Manual, itshould notberegarded
as an infallible guidetocurrent specifications ofany
particular component orvehicle.
This Manual doesnotconstitute anoffer forsale of
any particular component orvehicle. Rover/Land
Rover Dealers arenotagents ofRover/Land Rover
and have...

MANUALGEARBOX
GENERAL DATA 1
REVISED: 12/96
GENERAL
DATA
NEWSERVICELIMIT
Baulk ringclearances 0.5mm (0.02 in)
1st gear endfloat 0.05-0.20 mm
(0.002 -0.008 in) 0.327mm(0.013 in)
2nd gear endfloat 0.04-0.21 mm
(0.0016 -0.0083 in)0.337 mm(0.13 in)
3rd gear endfloat 0.11-0.21 mm
(0.004 -0.0083 in)0.337mm(0.13 in)
Adjust 5th-reverse hub-shim to- 0.005-0.055 mm
(0.002 -0.022 in) 0.055mm(0.022 in)
Reverse gearidlershaft clearance 0.04-0.38 mm
(0.0016 -0.015 in) 0.38mm(0.015 in)
Mainshaft endfloat 0.01-0.06 mm...

MANUALGEARBOX
TORQUE WRENCH SETTINGS 1
REVISED: 12/96
TORQUE
WRENCH SETTINGS
Oil pump toextension case 6Nm
Attachment platetogearcase 8Nm
Attachment platetoremote housing 8Nm
Bottom covertoclutch housing 8Nm
Breather baffle 8Nm
Clip toclutch release lever 8Nm
Cover togear change housing 8Nm
Spool retainer togear case 8Nm
Torsion springlocknut -adjusting screw 8Nm
Screw -gear lever retention 8Nm
Breather 15Nm
Gear leverretainer bolt 15Nm
Reverse inhibitorshaft 16Nm
Reverse lightswitch 24Nm
Transfer...

MANUALGEARBOX
SERVICE TOOLS 1
SERVICE
TOOLS
NOTE:Wheretheuse ofspecial toolsisspecified, onlythese toolsshould beused toavoid the
possibility ofpersonal injuryandordamage tocomponents.
Land Rover Number RoverNumber Description
LRT-37-001 18G47BAAdaptorinputshaft
bearing
LRT-37-002 18G47BAXConversionkit
LRT-37-004 18G284AAHAdaptorforinput shaft
pilot bearing track
LRT-37-009 18G705Puller,bearing andoil
seal collar remover
LRT-37-010 18G705-1AAdaptorformainshaft
oil seal collar
LRT-37-014...

MANUALGEARBOX
DESCRIPTION ANDOPERATION 1
REVISED: 12/96
DESCRIPTION The
R380 5speed allsynchromesh gearbox
comprises aninput shaft, output shaft,layshaft and
reverse idlershaft .
Gearbox casingsconsistofafront cover, gearcase,
centre plateandextension housing,allcasings are
located bydowels andsealed.
Selector forksfor1st/2nd and3rd/4th gearsare
located onasingle selector shaftinside themain
gearcase whilsttheselector forkforfifth and reverse
gear islocated onthe same selector shaftinside the
extension...

MANUALGEARBOX
2 DESCRIPTION ANDOPERATION REVISED:12/96  

MANUALGEARBOX
DESCRIPTION ANDOPERATION 3
REVISED: 12/96
GEARBOX
COMPONENTS -GEARS AND
SHAFTS
1. 3rd/4th gearselector fork
2. Interlock spool
3. 1st/2nd gearselector fork
4. Selector shaftyokepins
5. Selector shaft
6. Reverse/5th gearselector fork
7. Selector quadrant -Type Agearbox
8. Selector yoke-Type B/Dgearbox
9. Selector yoke-Type Cgearbox
10. Input shaftfronttaper bearing
11. Input shaft
12. 4thgear synchro ring
13. Pilot taper bearing
14. Spacer
15. 3rd/4th gearsynchro hubandsleeve
16. 3rdgear...