Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual

MANUALGEARBOX
OVERHAUL 1
GEAR
BOXDISMANTLE
Service repairno-37.20.04
Clutch housing -Type Agearbox -Remove
1.If fitted:remove anddiscard clipsretaining
clutch release bearing pads,remove bearing
and clutch release lever,recover pads.
2.Remove 2bolts securing releaseleverpivot
post, remove post.
3. Remove 6bolts securing clutchhousing to
gearbox, removehousing.
NOTE:Dowellocated.    

MANUALGEARBOX
2 OVERHAUL
Clutch
housing -Type Bgearbox -Remove
1. Remove clutchrelease bearing.
2. Remove boltsecuring springcliptoclutch
release lever,remove clip.
3. Remove clutchrelease lever.
4. Remove Cclip from release leverpivotpost,
discard clip.
5. Remove 6bolts securing clutchhousing to
gearbox, removehousing.
NOTE:Dowellocated. Clutch
housing -Type Cgearbox -Remove
1. Pull clutch release leveroffpivot post, remove
lever andclutch release bearing.
2.Remove 6bolts securing clutchhousing to...

MANUALGEARBOX
OVERHAUL 3
Clutch
housing -Type Dgearbox -Remove
NOTE: TypeDgearboxes haveastandard
clutch housing adaptorwhichmates with
both V8and diesel engine clutch
housings.The aboveillustration showsthe
gearbox removed atthe clutch housing adaptor
with theclutch housing adaptor(containing the
clutch mechanism) stillfitted tothe engine.
1.Remove 2bolts securing releaseleverpivot
post. Remove post.
2. Remove 6bolts securing adaptorhousing to
gearbox. Removeadaptorhousing. Gear
change/selector...

MANUALGEARBOX
4 OVERHAUL
Remote
housing -Type Agearbox -Remove
1. Noting theirfitted position, remove3bolts
securing remotehousing, removehousing.
NOTE:Dowellocated.
Gear change/selector housings-Type Bgearbox
- Remove
1. Remove 2Torx screws securing gearchange
housing cover,remove cover;recover sealing
rubber.
2. Remove 4bolts securing transferboxselector
housing, removehousing.
3. Noting theirfitted position, remove3bolts
securing gearchange housing, remove
housing.
NOTE: Dowellocated.    

MANUALGEARBOX
OVERHAUL 5
Selector
quadrant -Type Agearbox -Remove
1. Remove anddiscard setscrew securing
selector quadrant.
2. Move selector shaftforwards, remove
quadrant.
Gear change leveryoke-Type Bgearbox -
Remove
1. Remove anddiscard setscrew securing yoke.
2. Move selector shaftforwards, removeyoke. Remote
gearchange -Type Cgearbox -Remove
1. Noting fittedpositions ofmounting rubbersand
washers, Rremove 2bolts securing remote
gear change toextension housing,recover
washers andmounting rubbers.
2....

MANUALGEARBOX
6 OVERHAUL
Remote
gearchange -Type Dgearbox -Remove
1. Remove 4bolts securing remotegearchange
to extension housing.
2. Release remotegearchange fromextension
housing.
Gear change leveryoke-Type Dgearbox -
Remove
1. Remove anddiscard setscrew securing yoke.
2. Move selector shaftforwards. Removeyoke. Extension
housing-Types Aand Bgearbox -
Remove
1. Thread a12mm boltintotheend ofthe output
shaft andusing toolLRT-37-009 and
LRT-37-010 withdrawoilseal collar.
2.Remove reverse/5th gearselector...

MANUALGEARBOX
OVERHAUL 7
4.Place asuitable container underneath thebox
to catch anyoilspillage andremove the
extension housing.
5. Remove oilfilter.
6. Secure centreplatetogear casing with2bolts
8 x35mm. Extension
housing-Type Cgearbox -Remove
1. Remove anddiscard self-locking nutsecuring
selector shaftpintoselector shaft;remove pin.
2. Carefully prisespeedometer pinionhousing
and gear outofextension housing,removeand
discard Oring.
3. Remove 5thgear spool retainer, removeand
discard Oring.
4. Noting...

MANUALGEARBOX
8 OVERHAUL
Extension
housing-Type Dgearbox -Remove
1. Remove reversegear/5th gearselector spool
retainer.
2. Remove 10bolts securing extension caseto
main gearcase, notingposition oflonger bolts.
3. Place asuitable container underneath thebox
to catch anyoilspillage.
4. Using asoft faced mallet, tapextension
housing freefrom itslocation dowels.
5. Remove extension housing.
6. Remove oilfilter.
5th and Reverse gear-Remove    

MANUALGEARBOX
OVERHAUL 9
1.
Using asuitable twolegged pullerremove 5th
gear layshaft supportbearingtrackfromthe
end oflayshaft.
2. Using toolLRT-37-023 tohold the5thlaygear,
remove the5thlaygear nut.
3. Remove thrustcollarsegments, retainingring
and segments, driftouttherollpin.
4.
Later gearboxes:Remove splitwasher
securing 5thlaygear toshaft.
5. Remove 5thlaygear.
6. Remove mainshaft rearsupport bearingtrack
using toolsLRT-37-009 andLRT-37-024.
7. Remove 12mmboltfrom endofmainshaft.
8. Remove mainshaft...

MANUALGEARBOX
10 OVERHAUL
Mainshaft
andlayshaft -Remove
1. Align selector shaftpinwith slotincentre plate
and using wooden blocksandhide mallet,
drive offcentre plate.
2. Collect detentballand spring, remove bearing
tracks andshims.
3.Remove layshaft,mainshaft andselector shaft
from casing ascomplete unit.
4. Remove inputshaft, and4thgear baulk ring.(If
not already removed withmainshaft). Mainshaft
-Dismantle
1. Using LRT-99-002 andsupport barsunder 1st
gear, press mainshaft supportbearingfrom
mainshaft.