Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual

							MANUAL GEARBOX
TORQUE WRENCH SETTINGS1
TORQUE WRENCH SETTINGS
Oil pump to extension case 6 Nm (4.5 lbf.ft)
Attachment plate to gearcase 8 Nm (6 lbf.ft)
Attachment plate to remote housing 8 Nm (6 lbf.ft)
Splash shield bolts 8 Nm (6 lbf.ft)
Bottom cover to clutch housing 8 Nm (6 lbf.ft)
Breather baffle 8 Nm (6 lbf.ft)
Clip to clutch release lever 8 Nm (6 lbf.ft)
Cover to gear change housing* 8 Nm (6 lbf.ft)
Interlock spool retainer to gear case 8 Nm (6 lbf.ft)
Torsion spring locknut - adjusting screw 8 Nm (6 lbf.ft)
Screw - gear lever retention 8 Nm (6 lbf.ft)
Breather 15 Nm (11 lbf.ft)
Gear lever cap retainer bolt 15 Nm (11 lbf.ft)
Reverse inhibitor shaft 16 Nm (12 lbf.ft)
Reverse light switch 24 Nm (17 lbf.ft)
Transfer box to remote housing bolts 25 Nm (18 lbf.ft)
Bias adjustment plate bolts* 25 Nm (18 lbf.ft)
Selector quadrant setscrew* 25 Nm (18 lbf.ft)
Gear change lever yoke setscrew* 25 Nm (18 lbf.ft)
Bridge plates to gear change housing* 25 Nm (18 lbf.ft)
Extension case to gear case* 25 Nm (18 lbf.ft)
Front cover to gear case* 25 Nm (18 lbf.ft)
Gear change housing to extension case 25 Nm (18 lbf.ft)
Gear lever housing to remote housing 25 Nm (18 lbf.ft)
Guide - clutch release sleeve to clutch housing 25 Nm (18 lbf.ft)
Mounting bracket 25 Nm (18 lbf.ft)
Pivot clutch lever to clutch housing 25 Nm (18 lbf.ft)
Pivot plate to clutch housing 25 Nm (18 lbf.ft)
Plug - detent ball and spring* 25 Nm (18 lbf.ft)
Plunger housing to gear change housing 25 Nm (18 lbf.ft)
Remote selector housing to extension case 25 Nm (18 lbf.ft)
Slave cylinder to clutch housing 25 Nm (18 lbf.ft)
Upper gear lever assembly to lower gear lever 25 Nm (18 lbf.ft)
Yoke to selector shaft 25 Nm (18 lbf.ft)
Oil filler/level plug 30 Nm (22 lbf.ft)
Oil drain plug 50 Nm (37 lbf.ft)
Clutch housing to gearbox 72 Nm (53 lbf.ft)
Output flange bolt 90 Nm (66 lbf.ft)
5th gear layshaft stake nut 220 Nm (162 lbf.ft)
Remote housing blanking plug* 30 Nm (22 lbf.ft)
Selector shaft trunnion setscrew* 25 Nm (18 lbf.ft)
Transfer box gaiter support plate bolts 15 Nm (11 lbf.ft)
Gate plate bolts 15 Nm (11 lbf.ft)
* Apply Loctite 290 to threads 
						

							MANUAL GEARBOX
SERVICE TOOLS1
SERVICE TOOLS
NOTE: Where the use of special tools is specified, only these tools should be used to avoid the
possibility of personal injury and or damage to components.
Land Rover Number Description
LRT-37-001/2 Adaptor for output shaft oil seal collar and bearing track
remover
LRT-37-004 Adaptor for input shaft pilot bearing track remover
LRT-37-009 Puller, bearing and oil seal collar remover
LRT-37-010 Adaptor for output shaft oil seal collar and bearing track
LRT-37-014 Output shaft rear oil seal replacer
LRT-37-015 Output shaft rear support bearing track and oil seal collar
replacer.
LRT-37-021 Adaptor for output shaft rear support bearing track and oil
seal collar replacer.
LRT-37-022 Adaptor for layshaft bearings
LRT-37-023 Layshaft holding tool
LRT-37-043 Adaptor for input shaft bearing
LRT-37-043/2 Adaptor
LRT-37-044 Adaptor for layshaft bearings
LRT-51-003 Flange holder
LRT-99-002 Hand press
LRT-99-004 Impulse extractor 
						

							MANUAL GEARBOX
DESCRIPTION AND OPERATION1
DESCRIPTION
The R380 5 speed all synchromesh gearbox
comprises an input shaft, output shaft, layshaft and
reverse idler shaft .
Gearbox casings consist of a front cover, gearcase,
centre plate and extension housing, all casings are
located by dowels and sealed.
Selector forks for 1st/2nd and 3rd/4th gears are
located on a single selector shaft inside the main
gearcase whilst the selector fork for fifth and reverse
gear is located on the same selector shaft inside the
extension housing.The input shaft, output shaft and layshaft are
supported by taper roller bearings with all gears
running on caged needle roller bearings. Output
shaft and layshaft bearings end float is controlled by
selective thrust washers located in the centre plate.
Lubrication is by an oil pump located in the
extension housing which directs oil via internal
drillings in the output shaft to lubricate the
components.
1.Output shaft 1st gear
2.Output shaft 2nd gear
3.Output shaft 3rd gear
4.Input shaft/4th gear
5.Output shaft 5th gear
6.Layshaft
7.Output shaft
8.Oil pump
9.Oil filter10.Breather
11.Single rail gear selector
12.1st/2nd synchromesh
13.Oil seals
14.3rd/4th gear synchromesh
15.5th/reverse gear synchromesh
16.Selective spacers (output shaft and layshaft
end float)
17.Selective spacer (5th gear/reverse hub) 
						

							MANUAL GEARBOX
2
DESCRIPTION AND OPERATION 
						

							MANUAL GEARBOX
DESCRIPTION AND OPERATION3
GEARBOX COMPONENTS - GEARS AND
SHAFTS
1.3rd/4th gear selector fork
2.Interlock spool
3.1st/2nd gear selector fork
4.Selector shaft yoke pins
5.Selector shaft
6.Reverse/5th gear selector fork
7.Selector quadrant - Type A gearbox
8.Gear change lever yoke - Type B/D gearbox
9.Gear change lever yoke - Type C gearbox
10.Input shaft front taper bearing
11.Input shaft
12.4th gear synchromesh ring
13.Pilot taper bearing
14.Spacer
15.3rd/4th gear synchromesh hub and sleeve
16.3rd gear synchromesh rings
17.3rd gear
18.Needle roller bearings
19.Output shaft
20.Roll pin
21.Needle bearing
22.2nd gear
23.2nd gear synchromesh rings
24.2nd/1st gear synchromesh hub and sleeve
25.1st gear synchromesh rings
26.1st gear
27.Needle roller bearing
28.Bush29.Output shaft taper bearing
30.Selective shims
31.Selective washer
32.Bush
33.Needle roller bearing
34.Reverse gear
35.Reverse gear synchromesh ring
36.Reverse/5th gear synchromesh hub and sleeve
37.Circlip
38.Needle roller bearings
39.5th gear synchromesh ring
40.5th gear
41.5th gear segments
42.5th gear segment retaining ring
43.Output shaft rear support bearing
44.Layshaft support bearing
45.Layshaft
46.Layshaft support bearing
47.Selective shims
48.Layshaft reverse gear
49.Layshaft 5th gear
50.Split washer - later gearboxes
51.5th gear nut
52.Layshaft rear support bearing
53.Spacer
54.Reverse idler gear
55.Needle roller bearing
56.Reverse idler shaft 
						

							MANUAL GEARBOX
4
DESCRIPTION AND OPERATION 
						

							MANUAL GEARBOX
DESCRIPTION AND OPERATION5
GEARBOX CASINGS
1.Front cover - Early gearboxes
2.Front cover - Later gearboxes
3.Input shaft oil seal
4.Oil filler/level plug
5.Oil drain plug
6.Sealing washer
7.Gearcase
8.Interlock spool retainer, bolt and’O’ring - if
fitted
9.Centre plate
10.Locating dowels
11.Selector plug, detent balls and springs
12.Splash shield and bolt
13.Extension housing - Types A and B gearbox
14.Gate plate and bolt
15.Interlock spool retainer, bolt and’O’ring
16.Inhibitor cam spring
17.Inhibitor cam
18.Reverse inhibitor shaft
19.Output shaft oil seal collar
20.Oil seal
21.Oil pump
22.’O’ring
23.Reverse light switch
24.Oil cooler by-pass and bolt
25.’O’ring
26.Oil pick-up pipe27.Oil filter
28.Oil pick-up ring
29.Oil cooler adaptor
30.Bolt
31.’O’ring
32.Extension housing - Type C gearbox
33.Gate plate and bolt - Type C gearbox
34.Inhibitor cam end plate and bolt - Type C
gearbox
35.Interlock spool retainer, bolt and’O’ring - Type
C gearbox
36.Selector shaft oil seal - Type C gearbox
37.Spacer - Type C gearbox
38.Speedometer pinion - Type C gearbox
39.Oil seal - Type C gearbox
40.Output shaft drive flange - Type C gearbox
41.’O’ring - Type C gearbox
42.Spacer - Type C gearbox
43.Tab washer - Type C gearbox
44.Drive flange bolt - Type C gearbox
45.Drive flange propeller shaft bolt - Type C
gearbox
46.Support bracket - Type C gearbox
47.Extension housing - Type D gearbox
48.Oil seal - Type D gearbox
49.Interlock spool retainer, bolt and’O’ring - Type
D gearbox