Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual
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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 gearbox, removeclutchhousing. NOTE: 2longest boltsarefitted atdowel locations andhave plain washers under their heads.
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 housings-Type Agearbox - Remove 1. Remove 4bolts securing gearchange housing, remove housing. NOTE:Dowellocated. 2. Remove 4bolts securing transferboxselector housing, removehousing.
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. Remove 2bolts securing remotegearchange bracket toextension housing,recover washers and mounting rubbers. 3. Release remotegearchange fromextension housing, disconnect selectorrodfrom selector shaft pin.
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 spool retainer. 3. Remove 10bolts securing extension casing noting position oflonger bolts.
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 theirfitted position, remove10bolts securing extension housingtogearcase. 5. Using asoft faced mallet, tapextension housing tofree itfrom locating dowels. 6. Remove extension housing. NOTE:Speedometer drivegearmaybea tight fiton output shaftandthiscan prevent removal ofextension housing. Insert suitable blocksofwood between extension housingandcentre plateandcarefully lever extension housingawayuntildrive gearis released. 7. Remove anddiscard selector shaftoilseal. 8. Secure centreplatetogearcase with2bolts 8 x 35mm.
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 5thgear withsynchromesh baulk ring. 9. Remove mainshaft 5thgear splitneedle roller bearing. 10. Remove circlipsecuring 5thgear synchromesh hub. 11. Rotate selector spoolclearofsynchro hubfork and remove 5thand reverse synchromesh hub assembly completewithforkand spool. 12. Remove mainshaft reversegearcomplete with needle rollerbearing andbush noting selectable spacerbetween reversegearbush and centre platebearing. 13. Remove layshaftreversegear. 14.Remove centreplatedetent plug,spring and ball. 15. Remove 2bolts securing spoolretainer, remove retainer. 16. Remove slavebolts.
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.