Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual

MANUALGEARBOX
OVERHAUL 11
2.Remove 1stgear, bushneedle bearing and
synchromesh baulkrings.
3. Remove 1st/2ndgearsynchromesh selector
hub, 2ndgear synchromesh baulkrings,
second gearandneedle bearing.
4. Invert mainshaft andusing LRT-99-002 and
support barsunder 3rdgear, press offpilot
bearing 5.
Remove spacer,3rd/4thgearsynchromesh
selector hub,synchromesh baulkrings, 3rd
gear andneedle bearing.    

MANUALGEARBOX
12 OVERHAUL
Gearbox
casing
Degrease andclean allcomponents. Inspectcasing
for damage, cracksandstripped threads.
1. Fitlevel plug.
2. Fitnew copper washer todrain plug.
Front Cover -Dismantle
1. Remove frontcover andremove bearing
tracks. Checkthatspring clipsareintact.
2. Remove oilseal from cover. DONOT fitnew
seal atthis stage. Centre
plate-Dismantle
1. Remove bearingtracksandshims andcheck
for wear anddamage.
2. Inspect fordamage andselector railbore for
wear.
3. Remove...

MANUALGEARBOX
OVERHAUL 13
Extension
housing-Types Aand Bgearbox -
Overhaul
1. Examine fordamage tothreads andmachined
faces.
NOTE: TypesAand Bgearbox extension
housing shown.
2. Remove threescrews andremove oilpump.
3. Remove oilpick-up pipeandcheck for
obstruction.
4. Drift outlayshaft supportbearing.
5. Remove mainshaft rearoilseal.
6. Drift outmainshaft supportbearingandoilpick
up ring.
7. Remove shaftretaining reverseinhibition cam.
8. Remove reverseinhibition camandspring.
9. Remove...

MANUALGEARBOX
14 OVERHAUL
Reassembly
1. Smear alight coat ofpetroleum jellyintothe
pump recess.
2. Renew Oring and press pump unitfirmly into
recess.
NOTE: Ensure TOPmarking onpump is
to top ofcasing.
3. Tap pump lightly atedges untilfullyhome.
NOTE: Ensure goodthread engagement
before tightening.
4.Fitnew mainshaft supportbearing.
5. Fitnew mainshaft rearoilseal using tool
LRT-37-014.
6. Fitnew Layshaft supportbearing.
7. Fitnew oilpick-up ring(Align tagwith centre of
drain slot).
8. Examine gateplate...

MANUALGEARBOX
OVERHAUL 15
4.Remove extension fromlower gearlever.
5. Remove boltand special washer securing
lower gearlever.
6. Carefully withdrawlowergearlever from
housing ensuring thatspring loaded nylonpad
is retained duringremoval.
WARNING: Personalinjurymayresult if
pad isnot retained.
7. Release nylonpad,recover spring.
8. Clean allcomponents. Inspection
1. Check lowergearlever ballpinforwear,
replace ifnecessary.
CAUTION: Iflower gearlever isto be
replaced thenballpinseating, locatedin
remote...

MANUALGEARBOX
16 OVERHAUL
Remote
housing -Type Agearbox
Dismantle
1. Remove setscrew securingtrunniontoselector
shaft, remove trunnion.
2. Remove anddiscard circlipsecuring ballpin
seating totrunnion, removeseating.
3. Slacken locknut,remove5thgear stopscrew.
CAUTION: Retainshim(s).
4.Remove blankingplugfrom endofremote
housing.
5. Remove setscrew securingquadrant to
selector shaft,remove quadrant.
6. Remove selectorshaftfromremote housing,
remove anddiscard Oring.
7. Remove anddiscard circlipretaining...

MANUALGEARBOX
OVERHAUL 17
Reassemble
1. Lubricate selectorshaftandnew Oring with
gearbox oil.
2. FitO ring toselector shaft.
3. Fitshaft toremote housing.
4. Position rollerstoquadrant, fitpin and secure
with new circlip.
CAUTION: Ensurethathead ofpin ison
opposite sideofquadrant toselector shaft
boss.
5. Fitquadrant toselector shaft.
6. Apply Loctite 270tothreads ofsetscrew, fit
and tighten setscrew.
7. Apply Loctite 270tothreads ofblanking plug,
fit and tighten plug.
8. Smear ballpinseating withmulti...

MANUALGEARBOX
18 OVERHAUL
Inspection
1. Check ballcross pinslots ingear change
housing forwear.
2. Check balland pins forwear.
3. Check biassprings fordistortion.
4. Replace worncomponents asnecessary.
Reassemble 1. Apply multi-purpose greasetoball and cross
pins.
2. Apply multi-purpose greasetonew Railko bush
and fitto gear change housing.
CAUTION: Ensurethattheslots ineach
bush arealigned withslots inhousing.
3. Lubricate anew oilseal withgearbox oil.
4. Fitoilseal using asuitable mandrel.
5. Position...

MANUALGEARBOX
OVERHAUL 19
Remote
gearchange -Type Dgearbox
NOTE: Theremote gearchange fittedto
Type Dgearboxes isnot repairable item.It
must berenewed ifitis found tobe
excessively worn. Inspection
1. Check selector rodbushes inremote housing
for wear.
NOTE: Bushes maybepressed inand out
of remote housing usingahand press and
suitable mandrel.
2. Check selector rodforwear, replace if
necessary.
3. Check anti-rattle spring fordistortion and
plunger forwear; replace ifnecessary.
4. Check gearlever ballpin,...

MANUALGEARBOX
20 OVERHAUL
Transfer
boxselector housing -Type Agearbox -
Overhaul Dismantle
1. Slide gaiter offgear lever.
2. Remove 4bolts securing gaitersupport plate
and gate plate.
3. Remove gaitersupport plateandgate plate,
discard gaskets.
4.Remove anddiscard springclipretaining
selector forkclevis pin.
5. Remove clevispinfrom selector fork,remove
and discard 2bushes.
6. Remove anddiscard circlipretaining nylonball
seating.
7. Remove gearlever, recover nylonseating and
ball
8. Remove 2countersunk...