Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual

MANUAL GEARBOX
22
OVERHAUL Reassemble
1.Lubricate selector shaft and new’O’ring with
gearbox oil.
2.Fit’O’ring to selector shaft.
3.Fit shaft to remote housing.
4.Position rollers to quadrant, fit pin and secure
with new circlip.
CAUTION: Ensure that head of pin is on
opposite side of quadrant to selector shaft
boss.
5.Fit quadrant to selector shaft.
6.Apply Loctite 290 to threads of setscrew, fit
setscrew and tighten to 25 Nm (18 lbf.ft).
NOTE: Early gearboxes: Fit new roll pin.
7.Apply Loctite 290 to...

MANUAL GEARBOX
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4.Lift lower lever assembly out of gear change
housing.
5.Remove and discard Railko bush.
6.Remove and discard oil seal from housing.
7.Clean all components.Inspection
1.Check ball cross pin slots in gear change
housing for wear.
2.Check ball and pins for wear.
3.Check bias springs for distortion.
4.Replace worn components as necessary.
Reassemble
1.Apply multi-purpose grease to ball and cross
pins.
2.Apply multi-purpose grease to new Railko bush
and fit to gear change housing....

MANUAL GEARBOX
24
OVERHAUL Remote gear change - Type C gearbox
Dismantle
1.Remove 2 bolts and 2 countersunk screws
securing bias spring bridge plates.
2.Remove bridge plates, bridge plate liners and
bias spring.
3.Remove 4 bolts and washers securing bottom
cover plate, remove plate.
4.Remove bolt securing gear lever cap, remove
cap.
5.Remove gear lever, recover anti-rattle spring
and plunger.
6.Remove pinch bolt securing selector rod yoke,
remove yoke.
7.Withdraw selector rod from remote housing.
8.Clean...

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Remote gear change - Type D gearbox
NOTE: With the exception of the reverse
light switch, the remote gear change fitted
to Type D gearboxes is not a repairable
item. It must be replaced if components are
found to be worn.Transfer box selector housing - Type A gearbox -
Overhaul
Dismantle
1.Slide gaiter off gear lever.
2.Remove 4 bolts securing gaiter support plate
and gate plate.
3.Remove gaiter support plate and gate plate,
discard gaskets.
4.Remove and discard spring clip...

MANUAL GEARBOX
26
OVERHAUL
6.Remove and discard circlip retaining nylon ball
seating.
7.Remove gear lever, recover nylon seating and
ball.
8.Remove 2 countersunk head screws securing
end cover to housing.
9.Remove end cover, remove and discard 2’O’
rings.
10.Withdraw cross shaft.
11.Remove selector fork, remove and discard 2
’O’rings.
12.Clean all components.Inspection
1.Check gaiter for splits and damage.
2.Check nylon seating and ball for wear, replace
if necessary.
CAUTION: Seating and ball should be...

MANUAL GEARBOX
OVERHAUL27
Synchromesh assemblies - Overhaul
1.Remove spring clips from both sides of
assembly.
2.Remove slippers and separate the hub from
the sleeve.
3.Examine all parts for damage and wear, check
spring clips for tension.
4.Check no excessive radial movement exists
between inner members and output shaft
splines.
5.Examine inner and outer splines for wear.
6.Examine the dog teeth for wear and damage.
NOTE: Example ’A’ shows a tooth in good
condition. Example ’B’ shows the rounded
corners...

MANUAL GEARBOX
28
OVERHAUL Checking baulk ring clearances
Check clearance of all baulk rings and gears by
pressing the baulk rings against the gear and
measuring the gap.
Minimum clearance - 0.5 mm (0.020 in).Input shaft - Overhaul
1.Examine the gear and dog teeth for wear and
damage.
2.UsingLRT-99-004andLRT-37-004remove
pilot bearing track.
CAUTION: Ensure that the bearing is
supported by the lip inside LRT-37-004.
3.UsingLRT-37-043andLRT-99-002remove
taper roller bearing. 

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4.UsingLRT-99-002, LRT-37-043and
LRT-37-043/2, fit a new taper roller bearing.
5.Support the shaft underLRT-99-002and using
a suitable mandrel, fit a new taper roller
bearing.Output shaft - Inspection
1.Examine bearing journals for wear and scores.
2.Examine splines for wear and damage.
3.Use an air line to check that the main oil feed
from pump and feed to spigot bearing are
clear.
4.Check oil feed holes to roller bearing are clear. 

MANUAL GEARBOX
30
OVERHAUL Layshaft - Overhaul
1.UsingLRT-99-002, LRT-37-022and
LRT-37-044, remove layshaft bearings.
2.Examine layshaft for wear and damage.
NOTE: Layshaft and layshaft 5th gear
fitted to later gearboxes are machined to
enable fitment of a split washer to prevent
gear movement on shaft. The modified layshaft,
gear and split washer may be fitted to early
gearboxes as an assembly.
3.Using pressLRT-99-002and a suitable
mandrel, positioned on bearing inner race, fit
new taper roller bearings. 

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Output shaft - Reassemble
1.Clamp output shaft in protected vice jaws,
output end upwards.
2.Fit 2nd gear needle roller bearing, 2nd gear
and synchromesh baulk rings on to output
shaft.
NOTE: Rotate each baulk ring to ensure
they locate onto each other.
3.Assemble the 1st and 2nd synchromesh
selector hub on to output shaft splines, noting
the 2nd gear side marking. Ensure that baulk
ring has located correctly inside hub.
NOTE: Rotate the ring slightly as the hub
is lowered....