Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual
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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 into5sections, Data,Torque Settings, ServiceTools,Description andfinally, Overhaul.To assistfilingofrevised information each sub -section isnumbered frompage 1. The individual overhaulitemsaretobe followed in the sequence inwhich theyappear. Itemsnumbered in the illustrations arereferred tointhe text. Overhaul operations includereference toService Tool numbers andtheassociated illustrationdepicts the tool inuse. Operations alsoinclude reference to wear limits, relevant data,torque figures, and specialist information anduseful assembly details. WARNINGS, CAUTIONSandNotes havethe following meanings: WARNING: Procedures whichmustbe followed precisely toavoid thepossibility of injury. CAUTION: Callsattention toprocedures which mustbefollowed toavoid damage to components. NOTE: Giveshelpful information. References Operations coveredinthis manual donot include reference totesting thevehicle afterrepair. Itis essential thatwork isinspected andtested after completion andifnecessary, aroad testofthe vehicle iscarried out,particularly wheresafety related itemsareconcerned. DimensionsThe dimensions quotedaretodesign engineering specification withService Limitswhere applicable. REPAIRS ANDREPLACEMENTS When replacement partsarerequired itis essential that only Rover/Land Roverrecommended partsare used.Attention isparticularly drawntothe following points concerning repairsandthefitting ofreplacement parts andaccessories. Safety features embodied inthe carmay be impaired ifother thanRover/Land Rover recommended partsarefitted. Incertain territories, legislation prohibitsthefitting ofparts nottothe manufacturers specification. Torque wrench settingfigures giveninthis Manual must beused. Locking devices, wherespecified, must befitted. Ifthe efficiency ofalocking deviceis impaired duringremoval itmust berenewed. The Terms ofthe vehicle Warranty maybe invalidated bythe fitting ofother thanRover/Land Rover recommended parts.AllRover/Land Rover recommended partshavethefullbacking ofthe vehicle Warranty. Rover/Land RoverDealers areobliged tosupply only recommended parts.
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 noauthority tobind themanufacturer by any expressed orimplied undertaking or representation. GEARBOX IDENTIFICATION The procedures giveninthis manual coveroverhaul of the R380 gearbox fittedtoarange ofvehicles and as such, certain differences existbetween gearboxes, particularlyinrespect ofthe extension housings, gearchange housings andtransfer box selector housings. Itis important thereforethat before starting work,thegearbox tobe overhauled is correctly identified. Identification canbemade by noting thegearbox serialnumber prefixstamped on the RH side ofthe gearbox casingandreferring to the following tablewhich listsfourtypes ofgearbox, A, B,Cand Dtogether withtheir appropriate serial number prefixes. NOTE:Thegearbox typeslistedareonly intended asan aid toidentification anddo not relate togearbox partnumbers ora particular vehicle. Overhaul operations inthis manual listthe applicable gearboxtypereferred toand itis important thattherelevant operation isfollowed. Type Agearbox prefixes: -50A; 51A;56A;58A; 60A; 61A; Type Bgearbox prefixes: -53A; 55A;63A Type Cgearbox prefix:-18A Type Dgearbox prefixes: -64A; 65A
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 (0.0004 -0.0024in) 0.06mm(0.0024 in) Layshaft endfloat 0.01-0.06 mm (0.0004 to0.0024 in)0.06 mm(0.0024 in) Lubricants ATFM2C33 For G Capacities Oilcooler fitted=3.4 litres Non oilcooler type=2.9 litres Sealants Jointfaces -Hylosil RTV102 Available throughUnipart Bolts andfiller plug -Loctite 270orMarston Bentley Hylogrip 640(studlock)
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 boxtoremote housing bolts 25Nm Bias adjustment platebolts 25Nm Selector quadrant setscrew 25Nm Gear change leveryokesetscrew 25Nm Adjustment platetogear change housing 25Nm Extension casetogear case 25Nm Front cover togear case 25Nm Gear change housing toextension case 25Nm Gear leverhousing toremote housing 25Nm Guide -clutch release sleevetobell housing 25Nm Mounting bracket 25Nm Pivot clutch levertobell housing 25Nm Pivot platetobell housing 25Nm Plug -detent balland spring 25Nm Plunger housing togear change housing 25Nm Remote selectorhousing toextension case25Nm Slave cylinder toclutch housing 25Nm Upper gearlever assembly tolower gearlever 25Nm Yoke toselector shaft 25Nm Filler plug 30Nm Oil level plug 30Nm Oil drain plug 50Nm Clutch housing togearbox 72Nm Output flangebolt 90Nm 5th gear layshaft stakenut 220Nm
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 18G1422Mainshaftrearoilseal replacer LRT-37-015 18G1431Mainshaftrearsupport bearing trackandoil seal collar replacer. LRT-37-021 -Adaptorformainshaft rear support bearing track andoilseal collar replacer. LRT-37-022 -Adaptorforlayshaft bearings LRT-37-023 -Layshaftholdingtool LRT-37-024 -Rearmainshaft bearing trackremover LRT-51-003 18G1205Flangeholder LRT-99-002 M547Handpress LRT-99-004 18G284Impulseextractor Service toolsmust beobtained directfromthemanufacturers: V.L.Churchill, P.O. BoxNo.3, London Road, Daventry,Northants, NN11.4NF England
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 housing. The input shaft, output shaftandlayshaft are supported bytaper rollerbearings withallgears running oncaged needle rollerbearings. Output shaft andlayshaft bearings endfloat iscontrolled by selective thrustwashers locatedinthe centre plate. Lubrication isby an oilpump located inthe extension housingwhichdirects oilvia internal drillings inthe output shafttolubricate the components. 1. Mainshaft 1stgear 2. Mainshaft 2ndgear 3. Mainshaft 3rdgear 4. Primary inputshaft/4th gear 5. Mainshaft 5thgear 6. Layshaft 7. Mainshaft 8. Lubrication pump 9. Oil filter 10. Breather 11. Single railgear shift 12. 1st/2nd synchromesh 13. Oilseals 14. 3rd/4th gearsynchromesh 15. 5th/reverse gearsynchromesh 16. Selective spacers(mainshaft &layshaft end float) 17. Selective spacer(5thgear/reverse hub)12/96
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 synchro rings 17. 3rdgear 18. Needle rollerbearings 19. Mainshaft (outputshaft) 20. Roll pin 21. Needle bearing 22. 2ndgear 23. 2ndgear synchro rings 24. 2nd/1st gearsynchro hubandsleeve 25. 1stgear synchro rings 26. 1stgear 27. Needle rollerbearing 28. Bush 29. Mainshaft taperbearing 30. Selectable shims 31. Selectable washer 32. Bush 33. Needle rollerbearing 34. Reverse gear 35. Reverse gearsynchro ring 36. Reverse/5th gearsynchro hubandsleeve 37. Circlip 38. Needle rollerbearings 39. 5thgear synchro ring 40. 5thgear 41. 5thgear segments 42. 5thgear segment retainingring 43. Mainshaft rearsupport bearing 44. Layshaft supportbearing 45. Layshaft 46. Layshaft supportbearing 47. Selectable shims 48. Layshaft reversegear 49. Layshaft 5thgear 50. Split washer -later gearboxes 51. 5thgear nut 52. Layshaft rearsupport bearing 53. Spacer 54. Reverse idlergear 55. Needle rollerbearing 56. Reverse idlershaft