Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual
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R380 GEARBOX OVERHAUL MANUAL This Overhaul Manual contains information applicable to the following models: New Range Rover Range Rover Classic 1995 Models on Discovery 1995 Models on Defender 1995 Models on Discovery 2 Publication Part No.LRL 0003ENG - 3rd Edition Land Rover 2000 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior permission from Land Rover.
INTRODUCTION CONTENTS Page INTRODUCTION INTRODUCTION 1...................................................................................................... REPAIRS AND REPLACEMENTS 1........................................................................... SPECIFICATION 2...................................................................................................... GEARBOX IDENTIFICATION 2...................................................................................
INTRODUCTION INTRODUCTION1 INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevant sub - section is given at the bottom of each page. This manual contains procedures for overhaul of the R380 gearbox on the bench with the clutch and, if applicable, the transfer box removed. For all other information regarding Adjustments, Removal of oil seals, clutch, transfer box and gearbox unit, consult the appropriate Repair Manual for the model concerned. This manual is divided into 5 sections, Data, Torque Settings, Service Tools, Description and finally, Overhaul.To assist filing of revised information each sub - section is numbered from page 1. The individual overhaul items are to be followed in the sequence in which they appear. Items numbered in the illustrations are referred to in the text. Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool in use. Operations also include reference to wear limits, relevant data, torque figures, and specialist information and useful assembly details. WARNINGS, CAUTIONSandNOTEShave the following meanings: WARNING: Procedures which must be followed precisely to avoid the possibility of injury. CAUTION: Calls attention to procedures which must be followed to avoid damage to components. NOTE: Gives helpful information.References Operations covered in this manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary, a road test of the vehicle is carried out, particularly where safety related items are concerned. Dimensions The dimensions quoted are to design engineering specification with Service Limits where applicable. REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Land Rover recommended parts are used. Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories. Safety features embodied in the car may be impaired if other than Land Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer’s specification. Torque wrench setting figures given in this Manual must be used. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. The Terms of the vehicle Warranty may be invalidated by the fitting of other than Land Rover recommended parts. All Land Rover recommended parts have the full backing of the vehicle Warranty. Land Rover Dealers are obliged to supply only recommended parts.
INTRODUCTION 2 INTRODUCTION SPECIFICATION Land Rover are constantly seeking to improve the specification, design and production of their vehicles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular component or vehicle. This Manual does not constitute an offer for sale of any particular component or vehicle. Land Rover Dealers are not agents of Land Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.GEARBOX IDENTIFICATION The procedures given in this manual cover overhaul of the R380 gearbox fitted to a range of vehicles and as such, certain differences exist between gearboxes, particularly in respect of the extension housings, gear change housings and transfer box selector housings. It is important therefore that before starting work, the gearbox to be overhauled is correctly identified. Identification can be made by noting the gearbox serial number prefix stamped on the RH side of the gearbox casing and referring to the following table which lists four types of gearbox, A, B, C and D together with their appropriate serial number prefixes. NOTE: The gearbox types listed are only intended as an aid to identification and do not relate to gearbox part numbers or a particular vehicle. Overhaul operations in this manual list the applicable gearbox type referred to and it is important that the relevant operation is followed. Type A gearbox prefixes: - 50A; 51A; 56A; 58A; 60A; 61A; 66A; 68A; 70A; 74A Type B gearbox prefixes: - 53A; 55A; 63A; 67A; 69A; 73A Type C gearbox prefix: - 18A Type D gearbox prefixes: - 64A; 65A
MANUAL GEARBOX CONTENTS Page DATA GENERAL DATA 1...................................................................................................... TORQUE WRENCH SETTING TORQUE WRENCH SETTINGS 1.............................................................................. SERVICE TOOLS SERVICE TOOLS 1..................................................................................................... DESCRIPTION AND OPERATION DESCRIPTION 1......................................................................................................... GEARBOX COMPONENTS - GEARS AND SHAFTS 3.............................................. GEARBOX CASINGS 5............................................................................................... GEAR CHANGE HOUSING - TYPE A GEARBOX 7................................................... GEAR CHANGE HOUSING - TYPE B GEARBOX 9................................................... REMOTE GEAR CHANGE HOUSING - TYPE C GEARBOX 11................................ TRANSFER BOX SELECTOR HOUSING - TYPE A GEARBOX 13........................... OVERHAUL GEARBOX DISMANTLE 1........................................................................................... Clutch housing - Type A gearbox - Remove 1............................................................. Clutch housing - Type B gearbox - Remove 2............................................................. Clutch housing - Type C gearbox - Remove 2............................................................. Clutch housing - Type D gearbox - Remove 3............................................................. Gear change/selector housings - Type A gearbox - Remove 4................................... Remote housing - Type A gearbox - Remove 4........................................................... Gear change/selector housings - Type B gearbox - Remove 5................................... Selector quadrant - Type A gearbox - Remove 6......................................................... Gear change lever yoke - Type B gearbox - Remove 6............................................... Remote gear change - Type C gearbox - Remove 7................................................... Remote gear change - Type D gearbox - Remove 7................................................... Gear change lever yoke - Type D gearbox - Remove 8............................................... Extension housing - Types A and B gearbox - Remove 8........................................... Extension housing - Type C gearbox - Remove 9....................................................... Extension housing - Type D gearbox - Remove 10..................................................... 5th and Reverse gear - Remove 11............................................................................. Output shaft and layshaft - Remove 13....................................................................... Output shaft - Dismantle 14......................................................................................... Gearcase 15................................................................................................................ Front Cover - Remove 16............................................................................................ Front Cover - Early type - Dismantle 16....................................................................... Front Cover - Later type - Dismantle 17....................................................................... Centre plate - Dismantle 17......................................................................................... Extension housings - Overhaul 18............................................................................... Gear change/selector housings - Overhaul 19............................................................ Synchromesh assemblies - Overhaul 27..................................................................... Checking baulk ring clearances 28.............................................................................. Input shaft - Overhaul 28............................................................................................. Output shaft - Inspection 29......................................................................................... Layshaft - Overhaul 30................................................................................................. Output shaft - Reassemble 31.....................................................................................
MANUAL GEARBOX CONTENTS Page Reverse idler gear and centre plate - Reassemble 33................................................. Selectors - Inspection 33............................................................................................. Selectors - Reassemble 34.......................................................................................... GEARBOX REASSEMBLE 34..................................................................................... Output shaft and layshaft end float 34......................................................................... Shimming 34................................................................................................................ Assembling output shaft and layshaft to centre plate 35.............................................. Reverse and 5th gear - Reassemble 37...................................................................... Extension housing - Type A and B Gearbox - Refit 39................................................ Extension housing - Type C gearbox - Refit 40........................................................... Extension housing - Type D gearbox - Refit 40........................................................... Selector quadrant - Type A gearbox - Refit 41............................................................. Gear change lever yoke - Type B gearbox - Refit 41................................................... Gear change lever yoke - Type D gearbox - Refit 42................................................... Remote housing - Type A gearbox - Refit 42............................................................... Transfer box selector housing - Type A gearbox - Refit 43.......................................... Gear change housing - Type A gearbox - Refit 43....................................................... 5th gear stop screw adjustment - Type A gearbox 44.................................................. Transfer box selector housing - Type B gearbox - Refit 44.......................................... Gear change housing - Type B gearbox - Refit 45....................................................... Remote gear change - Type C gearbox - Refit 45....................................................... Remote gear change - Type D gearbox - Refit 46....................................................... Bias spring adjustment - Type A gearbox 46............................................................... Bias spring adjustment - Type B gearbox 47............................................................... Bias spring adjustment - Type C gearbox 47............................................................... Clutch housing - Type A gearbox - Refit 48................................................................. Clutch housing - Type B gearbox - Refit 48................................................................. Clutch housing - Type C gearbox - Refit 49................................................................. Adaptor housing - Type D gearbox - Refit 50...............................................................
MANUAL GEARBOX GENERAL DATA1 GENERAL DATA NEW SERVICE LIMIT Baulk ring clearances 0.5 mm (0.02 in) 0.5 mm (0.02 in) 1st gear end float 0.05 - 0.20 mm (0.002 - 0.008 in) 0.327 mm (0.012 in) 2nd gear end float 0.04 - 0.21 mm (0.0016 - 0.008 in) 0.337 mm (0.013 in) 3rd gear end float 0.11 - 0.21 mm (0.004 - 0.008 in) 0.337 mm (0.013 in) Adjust 5th - reverse hub - shim to:- 0.005 - 0.055 mm (0.0002 - 0.002 in) 0.055 mm (0.002 in) Reverse gear idler shaft clearance 0.04 - 0.38 mm (0.0016 - 0.015 in) 0.38 mm (0.015 in) Output shaft end float Early gearboxes:- 0.01 - 0.06 mm (0.0004 - 0.0024in) 0.06 mm (0.0024 in) Later gearboxes having letter K added to gearbox serial number:- 0.00 - 0.05 mm (0.00 - 0.002 in) 0.05 mm (0.002 in) Layshaft end float Early gearboxes:- 0.01 - 0.06 mm (0.0004 - 0.0024 in) 0.06 mm (0.0024 in) Later gearboxes having letter K added to gearbox serial number:- 0.0 - 0.05 mm (0.0 - 0.002 in) 0.05 mm (0.002 in)