Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual

MANUALGEARBOX
OVERHAUL 31
Reverse
and5thgear -Reassembly
1. Fitmainshaft reversegearselectable washer,
bush andneedle bearing.
2. Fitmainshaft reversegearandsynchromesh
baulk ring.
3. Fitlayshaft reversegear.
4. Assemble selectorspool,selector forkand
reverse /5thgear synchromesh hub.Fitasone
assembly tomainshaft splinesandselector
shaft. (Ensure synchromesh baulkringlocates
inside hub).
5. Fitnew circlip.
NOTE: Thefitof the circlip iscontrolled by
the selectable washerbehindthereverse
gear. Adjust to...

MANUALGEARBOX
32 OVERHAUL
12.Using toolLRT-37-015 andLRT-37-021 press
mainshaft rearsupport bearingtracktocollar
on mainshaft.
13. Apply smallamount ofheat andfitlayshaft rear
support bearing.
14.Fitcentre platedetent balland spring.
15. Fitand tighten plugto25 Nm.
NOTE: Patchlok plugmaybere-used
provided threadsareundamaged.
16. Move selector shaftandcheck thatdetent balls
can befelt toengage indetent. Extension
housing-Type Aand BGearbox -
Refit
1. Remove allslave boltsfromcentre plateand
casing.
2....

MANUALGEARBOX
OVERHAUL 33
5.Apply Hylosil RTV102toextension casespool
retainer, fitretainer andtighten boltto8Nm.
6. Using LRT-37-015 andLRT-37-21 presson
mainshaft oilseal collar. Extension
housing-Type Cgearbox -Refit
1. Lubricate anew selector shaftoilseal with
gearbox oil.
2. Fitselector shaftoilseal.
3. Refit oilfilter.
4. Apply Hylosil RTV102tomating surfaces.
5. Fitextension housingensuring oilpick -up
pipe locates infilter anddrive locates inoil
pump.
CAUTION: Donot use force, ifnecessary,
remove...

MANUALGEARBOX
34 OVERHAUL
Extension
housing-Type Dgearbox -Refit
1. Remove allslave boltsfromcentre plate.
2. Refit oilfilter.
3. Apply Hylosil RTV102tomating surfaces and
fit extension housing.Ensurethatoilpipe
locates infilter andthatroller bearings arenot
dislodged.
CAUTION: Donot use force. Ifnecessary,
remove extension housingandre-align oil
pump drive.
4. Bolt extension housingtocentre plateand
main casing.
5.Apply Hylosil RTV102andfitextension case
spool retainer, fitand tighten boltto8Nm....

MANUALGEARBOX
OVERHAUL 35
Gear
change leveryoke-Type Bgearbox -Refit
1. Position gearchange leveryokeonselector
shaft withballfacing towards outputshaft.
2. Apply Loctite 270tothreads ofanew setscrew,
fit and tighten screwto25 Nm.
CAUTION: Ensureendofsetscrew locates
in hole inselector shaft. Gear
change leveryoke-Type Dgearboxes -
Refit
1. Position gearlever yokeonselector shaftwith
ball facing towards outputshaft.
2. Apply Loctite 270tothreads ofnew setscrew.
Fit and tighten screwto25 Nm.
CAUTION:...

MANUALGEARBOX
36 OVERHAUL
Remote
housing -Type Agearbox -Refit
1. Apply Hylosil RTV102tomating surfaces and
fit to extension housing.
2. Position remotehousing toextension housing
and gearcase ensuringrollerslocatein
quadrant.
3. Fitbut donot fully tighten 3bolts inpositions
shown.
Transfer boxselector housing -Type Agearbox -
Refit
1. Smear anew gasket withgrease andfitto
remote housing.
2. Position transferboxselector housing to
remote housing.
3. Fitbut donot fully tighten 4bolts. Gear
change housing...

MANUALGEARBOX
OVERHAUL 37
Gear
change housing -Type Bgearbox -Refit
1. Apply Hylosil RTV102tomating surfaces of
extension housing.
2. Position gearchange housing toextension
housing ensuring thatgear lever passes
through centreofgear change leveryokeand
engages inthe gate plate.
3. Fitbolts andtighten to25 Nm.
Remote gearchange -Type Cgearbox -Refit
1. Apply lithium basedgrease toselector rod
yoke.
2. Position remotegearchange toextension
housing ensuring selectorshaftpinislocated
in selector rodyoke.
3....

MANUALGEARBOX
38 OVERHAUL
Bias
spring adjustment -Type Agearbox
NOTE: Thepurpose ofthis adjustment is
to set both bolts sothat thebias spring
legs apply equalpressure onboth ends of
the gear lever cross pinwhen thirdorfourth gear
is engaged. Thiswillensure thatwhen thelever
is in neutral, thegear change mechanism is
automatically alignedforthird orfourth gear.
1.Select thirdorfourth gear.
2. Adjust thetwo adjusting screwsuntilboth legs
of the spring areapproximately 0.5mm clear of
the cross pininthe gear...

MANUALGEARBOX
OVERHAUL 39
Bias
spring adjustment -Type Cgearbox
NOTE: Thepurpose ofthis adjustment is
to ensure thatwhen biasspring is
correctly adjusted, thegear change
mechanism isautomatically alignedfor3rd or
4th gear selection whengearlever isin neutral.
1. Adjust bothbiasspring adjustment boltsuntila
clearance of0.05mm existsbetween bothlegs
of bias spring andgear lever cross pin.
2. Apply alight load tomove gearlever tothe left
and adjust righthand boltuntil right hand legof
bias spring...

MANUALGEARBOX
40 OVERHAUL
Clutch
housing -Type Bgearbox -Refit
1. Position clutchhousing togearbox.
2. Fitsecuring bolts.
NOTE:The12x45mm boltsmustbefitted
through locating dowels.
3. Tighten boltsbydiagonal selection to72 Nm.
4. Apply lithium basedgrease topivot post,
release lever,socket andpush rod.
5. Fitanew Cclip topivot post, fitpost.
6. Fitspring cliptorelease lever,fitbut donot
tighten bolt. 7.
Position releaselevertopivot postensuring
spring clipislocated behindCclip; tighten
bolt.
8. Fitclutch...