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
0.005-0.055mm (0.0002-
0.0021in).
6. Fit5th gear splitneedle bearing.
7. Fit5th gear and5thgear synchromesh baulk
ring tomainshaft, fitlayshaft 5thgear.
8.
Later gearboxes:Fitsplit washer toretain
layshaft 5thgear.
NOTE: Bevelled sideofwasher mustface
towards gear.
9. Fitnew mainshaft thrustcollarrollpin. Locate
5th gear thrust segments andretaining ring.
10.Using LRT-37-023 tohold layshaft 5thgear,
tighten thelayshaft 5thgear nutto220 Nm.
11. Stake layshaft 5thgear nut.    
						

							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. Refit oilfilter.
3. Apply Hylosil RTV102tomating surfaces and
fit extension housingensuring oilpipe locates
in filter androller bearings arenotdislodged.
CAUTION: Donot use force, ifnecessary,
remove extension housingandre-align
oil pump drive.
4. Bolt extension housingtocentre plateand
main casing.    
						

							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 extension housingandre-align
oil pump drive.
6. Fitextension housingboltsandtighten by
diagonal selection to25 Nm.
7. Fitspacer
8. Position speedometer drivegearonoutput
shaft splines.
9. Using around nosed punch, carefully tap
speedometer drivegearintoposition.
10. Smear anew Oring with gearbox oiland fitto
speedometer pinionhousing.
11. Lubricate speedometer pinionwithsilicone
grease.
12. Fitspeedometer pinionhousing ensuring teeth
of pinion meshwiththose ofdriven gear.
13. Apply Hylosil RTV102andfit5th gear spool
guide. Tighten boltto8Nm.
14. Fitselector shaftpintoselector shaft,fitand
tighten anew self-locking nut.
15. Fitoutput flangetooutput shaft.
16. Fitnew Oring and spacer.
17. Fitnew tabwasher.
18. Fitoutput flangeboltand tighten to90 Nm.
19. Lock boltwith tabwasher.    
						

							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.
Selector quadrant -Type Agearbox -Refit
1. Position selectorquadrant toselector shaft.
2. Apply Loctite 270tothread ofanew setscrew.
Fit and tighten screwto25 Nm.
3. Move selector shafttoneutral position.
CAUTION: Ensureendofsetscrew locates
in hole inselector shaft.    
						

							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: Ensureendofsetscrew locates
in hole inselector shaft.    
						

							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 -Type Agearbox -Refit
1. Smear anew gasket withgrease andfitto
remote housing.
2. Position gearchange housing toremote
housing ensuring gearlever balliscorrectly
located.
3. Fitbut donot fully tighten 4bolts.
4. Tighten remotehousing, transferboxselector
housing andgear change housing boltsto25
Nm.
Transfer boxselector housing -Type Bgearbox -
Refit
1. Smear anew gasket withgrease andfitto
gearcase.
2. Position transferboxselector housing to
gearcase, fit4bolts andtighten to25 Nm  
						

							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. Fitbolts, washers andmounting rubbers
securing remotegearchange toextension
housing; donot tighten boltsatthis stage.
4. Fitbolts, washers andmounting rubbers
securing brackettoextension housing.
5. Tighten allbolts to30 Nm. Remote
gearchange -Type Dgearbox -Refit
1. Apply Hylosil RTV102tomating surfaces of
extension housingandremote gearchange
housing.
2. Position remotegearchange housing on
extension housing.Ensurethatgear lever ball
is correctly located.
3. Fitbolts andtighten to25 Nm.
5th gear stopscrew adjustment -Type A
gearbox
1. Select reverse gear.While applying light
pressure togear lever towards left,turn screw
clockwise untilitcontacts yoke.
2. Turn screw anti-clockwise until25mm free
play isfelt atknob, ensure 5thgear canbe
engaged.
3. Tighten locknut.
4. Check allother gears areselectable.    
						

							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 lever.
3. Apply alight load tothe gear lever inaleft
hand direction andadjust theright hand
adjusting screwdownward untiltheright hand
spring legjust makes contact withthecross
pin.
4. Repeat thesame procedure forthe lefthand
adjusting screw.
5. Lower bothadjusting screwsequalamounts
until theradial playisjust eliminated.
6. Tighten locknuts.
7. Return gearlever toneutral position androck
across thegate several times.Thegear lever
should returntothe third andfourth gate. Bias
spring adjustment -Type Bgearbox
1. Slacken biasadjustment platebolts. Select
fourth gearandmove leverfullytothe right.
2. Tighten adjustment platebolts.
3. Check adjustment iscorrect byselecting third
and fourth gears.
4.Fitsealing rubbertogear change housing,
apply Hylogrip 640toscrews andfitcover.    
						

							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 justcontacts gearlever cross pin.
3. Move gearlever tothe right andadjust left
hand bolt.
4. Check thatwith gear lever moved fullytothe
left and right, spring legsjustcontact gearlever
cross pin.
5. Select neutral thenrockgear lever across the
gate; when released, levershould returnto
3rd/4th position.
6. Tighten adjusting boltlocknuts. Clutch
housing -Type Agearbox -Refit
1. Position clutchhousing togearbox.
2. Fitsecuring bolts.
NOTE:The12x45mm boltsmustbefitted
through locating dowels.
3. Tighten boltsbydiagonal selection to72 Nm.
4. Fitpivot post, fitand tighten bolts.
5. Apply lithium basedgrease topivot post, pads
and push rod.
6. Position padstoclutch release lever,fitrelease
bearing.
7. Fitnew clips toretain pads.
NOTE: Clipsmaybecome displaced in
service withnoloss ofperformance.
8. Fitrelease lever.
9. Apply lithium basedgrease tosplines ofinput
shaft.    
						

							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 release bearing andretain usingnew
clips.
NOTE: Clipsmaybecome displaced in
service withnoloss ofperformance.
Clutch housing -Type Cgearbox -Refit
1. Position clutchhousing togearbox.
2. Fitsecuring bolts.
NOTE:The2longest boltsmustbefitted
at locating dowelpositions.
3. Tighten boltsbydiagonal selection to72 Nm.
4. Apply lithium basedgrease topivot post.
5. Fitrelease leverandclutch release bearing.
Adaptor housing -Type Dgearbox -Refit
1. Position adaptorhousing togearbox.
2. Fitsecuring bolts.
NOTE:Thetwolongest boltsmustbe
fitted atlocating dowelpositions.
3. Tighten boltsbydiagonal selection to72 Nm.
4. Apply lithium basedgrease topivot post.
5. Fitpivot postandsecure withtwobolts.