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 splashshieldifrequired.
4. Press outreverse idlergear shaft using
suitable pressandcheck forwear.
5. Remove idlergear, needle bearing andspacer
and check forwear anddamage.
6. Check centreplatedetent ballsforwear and
springs fordistortion, replaceasnecessary.
7. Check thatthreads ofdetent plugarenot
damaged.
NOTE: Patchlok plugmaybere-used
provided threadsareundamaged.   
						

							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 reverselightswitch andsealing
washer.
10. Remove gateplate.
11. Check allcomponents forwear andrenew as
required.
Type Cgearbox -A s for Aand BTypes and
including thefollowing:
12. Recover speedometer divegear andspacer.
13. Check speedometer drivegearforwear and
damage, renewifnecessary.
14. Check speedometer pinionforwear and
damage. Checkthatscrolling onshaft isclear;
renew pinionandshaft ifnecessary.
15. Check slotsin5th gear spool guide forwear,
renew spoolguide ifnecessary.
Type Cand Dgearboxes
CAUTION: Therear mainshaft oilseal
fitted toType Cand Dextension housings
is different toTypes Aand B.When
levering outseal, takecare nottodamage the
seal location surfaces.
NOTE:TypeDgearbox extension housing
shown.
1. Lever outmainshaft oilseal, taking carenotto
damage thelocation surfaces.    
						

							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 andrenew ifworn or
damaged.
9. Refit reverse lightswitch withnew copper
washer. Tightento24 Nm.
10. Refit reverse inhibition camandspring.
11. Apply Hylogrip 640andrefitshaft.
12. Refit oilpipe, bend uppermost. Gear
change/selector housings-Overhaul
Gear change housing -Type Agearbox
Dismantle
1. Using asuitable pieceoftubing, release both
ends ofbias spring fromballpins.
2. Slacken locknuts andremove biasspring
adjusting screws.
3. Drift outrollpin, remove biasspring.   
						

							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 housing shouldalsobereplaced.
2. Check nylonpadandspring forwear and
damage, replaceifnecessary.
3. Check biasspring rollpin fordamage, replace
if necessary.
Reassemble 1. Smear ballpinwith multi -purpose greaseand
fit spring andnylon pad.
2. Depress nylonpadagainst springpressure,
position lowergearlever inhousing.
CAUTION: Ensurenylonpadisfacing
away frombiasspring location.
3. Fitlower gearlever retaining boltand special
washer, tightenboltto15 Nm.
4. Fitextension tolower gearlever.
5. Position rollpin tohousing, fitroll pin.
6. Fitbias spring adjusting screwsandlocknuts.
7. Using asuitable pieceoftubing locateboth
ends ofbias spring overballpins.
NOTE: Donot adjust biasspring atthis
stage.   
						

							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 rollers
and pintoquadrant.
8. Remove pin,recover rollers.
Inspection 1. Check selector shaftandbore inremote
housing forwear.
2. Check quadrant rollersandpinforwear.
3. Check ballpinseating forwear.
4. Replace worncomponents asnecessary.   
						

							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 -purpose
grease.
9. Position ballpinseating intrunnion, secure
with anew circlip.
10. Position trunnion onselector shaft.
11. Apply Loctite 270tothreads ofsetscrew, fit
and tighten setscrew.
12. Fit5th gear stopscrew, fitbut donot tighten
locknut.
NOTE: 5thgear stopscrew adjustment is
carried outduring gearbox reassembly. Gear
change housing -Type Bgearbox
Dismantle
1. Remove boltsretaining biassprings.
WARNING: Toavoid personal injury,
restrain eachspring inturn with apair of
grips while thebolts arebeing removed.
2. Remove thetwo springs.
3.Remove remaining boltstorelease lowerlever
assembly.
4. Remove anddiscard Railkobush.
5. Remove anddiscard oilseal.    
						

							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 gearlever togear change housing
ensuring ballcross pinsarelocated inslots in
housing andRailko bush.
6. Position biasspring adjustment platetogear
change housing,
7. Apply Loctite 270tothreads of2short bias
adjustment platebolts.
8. Fitbolts tosecure frontofbias adjustment
plate andtighten to25 Nm.
9. Position biasspring topillar ensuring longest
end ofspring isagainst gearlever.
10. Apply Loctite 270tothreads of2long biasbias
adjustment platebolts.
11. Restrain biasspring usingasuitable pairof
grips,ensure shortendofbias spring is
positioned onoutside edgeofbolt hole.
WARNING: Personalinjurymayresult if
bias spring isnot retained.
12. Fitbolt and washer ensuring endofbias spring
is retained beneath washer;tightenboltto25
Nm.
13. Repeat procedure forremaining biasspring. Remote
gearchange -Type Cgearbox
Dismantle1. Remove 2bolts and2countersunk screws
securing biasspring bridge plates.
2. Remove bridgeplates, bridgeplateliners and
bias spring.
3. Remove 4bolts andwashers securing bottom
cover plate,remove plate.
4. Remove boltsecuring gearlever cap,remove
cap.
5. Remove gearlever, recover anti-rattle spring
and plunger.
6. Remove pinchboltsecuring selectorrodyoke,
remove yoke.
7. Withdraw selectorrodfrom remote housing.
8. Clean components.  
						

							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, cross pinsandbush
selector rodyoke ballsforwear, andreplace if
necessary. Ifyoke ballsareworn, remove and
discard circlip,pressballand seating outof
yoke.
5. Lubricate replacement balland seating with
multi -purpose greaseandpress intoyoke;
secure usingnewcirclip.
6. Check biasspring fordistortion, replaceif
necessary.
7. Check condition ofmounting rubbers,replace
as aset ifnecessary.
Reassemble 1. Lubricate selectorrodand bushes withmulti -
purpose grease,insertrodinremote housing.
2. Lubricate gearlever ballpinand selector rod
yoke ballswithmulti -purpose grease.
3. Fityoke toselector rod,fitand tighten pinch
bolt.
4. Assemble anti-rattle spring andplunger to
gear lever.
5. Fitgear lever ensuring ballpinislocated in
yoke andanti-rattle spring andplunger are
not displaced.
6. Fitgear lever cap,fitand tighten bolt.
NOTE: Donot fitbottom coverplateatthis
stage.
7. Slacken biasspring adjustment boltlocknuts.
8. Fitbias spring, bridgeplateliners andbridge
plates.
9. Fitand tighten boltsandcountersunk screws.
NOTE:Finaladjustment ofbias spring is
carried outafter remote gearchange is
fitted togearbox.   
						

							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 headscrews securing
end cover tohousing.
9. Remove endcover, remove anddiscard 2O
rings.
10. Withdraw crossshaft.
11. Remove selectorfork,remove anddiscard 2
O rings.
12. Clean allcomponents.