Land Rover R380 Gearbox Overhaul 1995 2nd Edition Rover Manual

							MANUALGEARBOX
OVERHAUL 21
Inspection
1. Check gaiterforsplits anddamage.
2. Check nylonseating andballforwear, replace
if necessary.
CAUTION: Seatingandballshould be
renewed asan assembly.
3. Check selector forkand clevis pinforwear.
4. Check crossshaftandendcover forwear.
5. Replace components asnecessary.
Reassemble 1. Smear newOrings withgearbox oiland fitto
selector fork,position forkinhousing.
2. Smear crossshaftwithmulti -purpose grease
and locate longest endofshaft inselector fork.
3. Smear newOrings withgearbox oiland fitto
end cover.
4. Position endcover oncross shaft, fitand
tighten countersunk screws.
5. Assemble balland nylon seating togear lever
ensuring thatgroove inseating istowards
cross shaft.
6. Smear balland nylon seating withmulti -
purpose greaseandlocate incross shaft;
retain withanew circlip.
7. Position newbushes togear lever, locate in
selector forkand fitclevis pin.
8. Fitnew spring cliptoretain clevis pin.
9. Position gateplate andgaiter support plateto
housing, usenew gaskets.
10. Fitretaining boltsandtighten to15 Nm.
11. Fitgaiter. Synchromesh
assemblies-Overhaul
1. Remove springclipsfrombothsides of
assembly.
2. Remove slippersandseparate thehub from
the sleeve.
3. Examine allparts fordamage andwear
including springclipsfortension.
4. Check noexcessive radialmovement exist
between innermembers andmainshaft splines.
5. Examine innerandouter splines forwear.   
						

							MANUALGEARBOX
22 OVERHAUL
6.Examine thedog teeth onallgears forwear
and damage.
NOTE: Example Ashows atooth ingood
condition. ExampleBshows therounded
corners ofaworn tooth.
7. Replace unitifexcessively worn.
Reassembly 8. Refit inner hubtosleeve.
NOTE: Hubsandsleeves haveamaster
spline combination andcanonly be
assembled oneway. Thesleeves are
further identified withaseries ofhalf moon
notches whichclearly identify whichsideofthe
assembly faceswhich gear.Ensure theslot in
the hub aligns withthecentre notchonthe
sleeve.
Assy Hub SleeveAgainst Gear
1st/2nd -1Notch 1st
2 gear
side -
2nd
3rd/4th -3Notches 3rd
- -4th
5th/Rev -5Notches 5th
9. Fitslippers andsecure withaspring eachside
of the synchromesh assemblyensuringthe
step oneach spring locates onadifferent
slipper.
NOTE: 5thand reverse synchromesh hubs
have different springsnotedbytheir
yellow colour. Checking
baulkringclearances
Check clearance ofall baulk ringsandgears by
pressing thebaulk ringsagainst thegear and
measuring thegap. Theminimum clearance
should be0.5mm (0.020in).
Inputshaft-Overhaul
1. Examine thegear anddogteeth forwear and
damage.
2. Using toolLRT-99-004 andLRT-37-004
remove pilotbearing track.
NOTE:Ensure thatthebearing is
supported bythe lipinside LRT-37-001.    
						

							MANUALGEARBOX
OVERHAUL 23
3.Using LRT-37-001 andLRT-99-002 remove
taper rollerbearing.
4. Support theshaft under LRT-99-002 andpress
in anew pilotbearing track.
5.Using LRT-99-002 ,Collets LRT-37-001 and
adapter LRT-37-002 fitanew taper bearing. Mainshaft
-Inspection
1. Examine bearingjournals forwear andscores.
2. Examine splinesforwear anddamage.
3. Use anairline tocheck thatthemain oilfeed
from pump andfeed tospigot bearing are
clear.
4. Check oilfeed holes toroller bearing areclear.     
						

							MANUALGEARBOX
24 OVERHAUL
Layshaft
-Overhaul
1. Using extractor toolLRT-99-002 andcollets
LRT-37-022 withdrawlayshaftbearings.
2. Examine layshaftforwear anddamage.
NOTE: Layshaft andlayshaft 5thgear
fitted tolater gearboxes aremachined to
enable fitment ofasplit washer toprevent
gear movement onshaft. Themodified layshaft,
gear andsplit washer maybefitted toearly
gearboxes asan assembly.
3.Using pressLRT-99-002 ,and support barsfit
new taper rollerbearings.  
						

							MANUALGEARBOX
OVERHAUL 25
Mainshaft-Reassembly
1. Clamp mainshaft inprotected vicejaws, output
end upwards.
2. Fit2nd gear needle rollerbearing, 2ndgear
and synchromesh baulkringsontomainshaft.
(Rotate eachbaulk ringtoensure theylocate
onto each other).
3.Assemble the1stand 2ndsynchromesh
selector hubonto mainshaft spline,
(note2nd
speed sidemarking).
Ensure thatbaulk ring
has located correctly insidehub.
(Rotate the
ring slightly asthe hub islowered).
4. Fit1st gear synchromesh baulkrings, needle
roller bearing, 1stgear andbush onto
mainshaft ensuringbaulkringslocate correctly
inside selector hub.
5. Using LRT-99-002 ,bearing guideLRT-37-019 ,
collets LRT-37-001 andadaptor LRT-37-002
press onmainshaft taperrollerbearing taking
care nottodisturb thelayofthe synchromesh
baulk ringsandgears. 6.
Check theend float ofthe 1stand 2ndgear
assembly usingafeeler gauge between the
gear andmainshaft bearing.
Maximum clearance:
1st gear: 0.05-0.20mm (0.002-0.008 in)
2nd gear: 0.04-0.21mm (0.0016-0.0083 in)
7. Invert mainshaft invice andfit3rd gear needle
roller bearing, thirdgear andsynchromesh
baulk rings.
8. Assemble 3rd/4thgearsynchromesh selector
hub (note 3rdspeed sidemarkings) onto
mainshaft splinestakingcaretolocate the
baulk ringsintorecesses inthe selector hub.
9. Fitspacer.   
						

							MANUALGEARBOX
26 OVERHAUL
10.Using LRT-99-002 pressonnew pilotbearing.
Check endfloat of3rd gear assembly asin
step 6.
Maximum clearance:
0.11 -0.21mm . Reverse
idlegear -Reassembly
1. Examine components forwear anddamage.2.Assemble reverseidlegear needle roller
bearing, idlegear, spacer andshaft andusing
suitable tool,press intocentre plate.
Maximum clearance:
0.04 -0.38mm (0.0016in -0.015in)   
						

							MANUALGEARBOX
OVERHAUL 27
Selectors
-Inspection
1. Examine selectorrailand pins forwear and
damage.
2. Examine selectorforksforwear anddamage.
NOTE: Theselector railand fork isonly
supplied asacomplete assembly.
3. Examine interlockspoolsforwear and
damage.
Selector quadrant -Type Agearbox
Examine selectorquadrant andcheck forwear.
Selector yoke-Type Band Dgearboxes
Selector yoke-Type Cgearbox
4. Remove snapringand examine selectoryoke
assembly.      
						

							MANUALGEARBOX
28 OVERHAUL
Assembling
selectors.
1.Rest 1st/2nd forkand shaft assembly onbench
and locate pininjaw offork.
2. Fitinterlock spooland3rd/4th forkand engage
spool injaw offork.
3. Slide spool andforktowards 1st/2ndselector
until slotinspool locates overpinkeeping the
spool engaged in3rd/4th forkjaw. GEARBOX
REASSEMBLE
Mainshaft andlayshaft endfloat
NOTE: Theendfloat setting forboth the
mainshaft andthelayshaft hastobe
determined beforethegear boxcanbe
reassembled. Thisisachieved byclamping the
mainshaft andlayshaft separately betweenthe
centre plateandmain casing andmeasuring the
movement oneach shaft withaDial test
indicator. The endfloat setting forthe mainshaft and
layshaft is0.01 -0.06mm (0.0004-0.0024in).
Shims tomake upthe required clearances are
placed underthebearing tracksofthe centre plate.
Shimming 1. Fitbearing trackstomain casing frontcover.
2. Fitfront cover tocasing without oilseal.
3. Clamp casing invice withfront cover
downwards.
4. Fitinput shaft. Donot fit4th gear baulk ring.
5. Fitmainshaft assemblytoinput shaft.
6. Fitmainshaft bearingshimandtrack tocentre
plate.   
						

							MANUALGEARBOX
OVERHAUL 29
7.Fitcentre plateandboltdown using8slave
bolts.
8. Fitlarge ballbearing torear ofmainshaft.
9. Mount dialtest indicator.
10. Rotate mainshaft tosettle bearings.
11. Liftmainshaft andnote reading.
12. Dismantle andsubstitute shimsifreading
incorrect.
13. Repeat procedure.
14. Remove mainshaft assemblyandrepeat
procedure forlayshaft.
15. Dismantle assemblyinpreparation for
assembly onstand. Assembling
mainshaftandlayshaft tocentre
plate
1. Secure centreplatetoworkstand.
2. Fitselected shimsandbearing tracks.
3. Fitinboard detentballand spring, usea
dummy bartotemporarily holdtheball in
place.
4. Check bothsynchromesh unitsareinneutral
and fitselector shaftassembly tomainshaft.
5. Fitmainshaft andselectors ascomplete unitto
centre platealigning pinwith slotinplate.
6. Fit4th gear synchromesh baulkring.    
						

							MANUALGEARBOX
30 OVERHAUL
7.Fitlayshaft whilstliftingmainshaft toclear
layshaft rearbearing.
8. Lubricate pilotbearing andfitinput shaft.
9.Fitoilseal tofront cover. Ensure sealisfitted
down toshoulder. ApplyHylosil RTV102to
front cover asshown.
NOTE: Earlytypeseal-unwaxed -
lubricate sealwith gearbox oil.
Later typeseal-wax coated -fit seal dry.
10. Fitbearing tracksandclips tomain caseandfit
front cover. Sealfixings withHylogrip 640.
11. Apply Hylosil RTV102andfitmain casing to
centre plate.
12. Bolt casing andcentre platetogether using2or
3 slave bolts.
13. Fitnew Oring and fitspool retainer.
14. Remove casingfromstand andclamp invice.