Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual
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MANUAL GEARBOX 2 OVERHAUL Clutch housing - Type B gearbox - Remove NOTE: Early type front cover illustrated. 1.Remove clutch release bearing. 2.Remove bolt securing spring clip to clutch release lever, remove clip. 3.Remove clutch release lever. 4.Remove’C’clip from release lever pivot post, discard clip. 5.Remove 6 bolts securing clutch housing to gearbox, remove housing. NOTE: Dowel located.Clutch housing - Type C gearbox - Remove 1.Pull clutch release lever off pivot post, remove lever and clutch release bearing. NOTE: Early type front cover illustrated. 2.Remove 6 bolts securing clutch housing to gearbox, remove clutch housing. NOTE: 2 longest bolts are fitted at dowel locations and have plain washers under their heads.
MANUAL GEARBOX OVERHAUL3 Clutch housing - Type D gearbox - Remove NOTE: Type D gearboxes have a standard clutch housing adaptor which mates with both V8 and diesel engine clutch housings.The above illustration shows the gearbox removed at the clutch housing adaptor with the clutch housing adaptor (containing the clutch mechanism) still fitted to the engine. NOTE: Early type front cover illustrated. 1.Remove 2 bolts securing release lever pivot post; remove post. 2.Remove 6 bolts securing adaptor housing to gearbox; remove adaptor housing.
MANUAL GEARBOX 4 OVERHAUL Gear change/selector housings - Type A gearbox - Remove 1.Remove 4 bolts securing gear change housing, remove housing. NOTE: Dowel located. 2.Remove 4 bolts securing transfer box selector housing, remove housing.Remote housing - Type A gearbox - Remove 1.Noting their fitted position, remove 3 bolts securing remote housing, remove housing. NOTE: Dowel located.
MANUAL GEARBOX OVERHAUL5 Gear change/selector housings - Type B gearbox - Remove 1.Remove 2 Torx screws securing gear change housing cover, remove cover; recover sealing rubber.2.Remove 4 bolts securing transfer box selector housing, remove housing. 3.Noting their fitted position, remove 3 bolts securing gear change housing, remove housing. NOTE: Dowel located.
MANUAL GEARBOX 6 OVERHAUL Selector quadrant - Type A gearbox - Remove 1.Remove and discard set screw securing selector quadrant. 2.Move selector shaft forwards, remove quadrant.Gear change lever yoke - Type B gearbox - Remove1.Remove and discard set screw securing yoke. 2.Move selector shaft forwards, remove yoke.
MANUAL GEARBOX OVERHAUL7 Remote gear change - Type C gearbox - Remove 1.Noting fitted positions of mounting rubbers and washers, remove 2 bolts securing remote gear change to extension housing, recover washers and mounting rubbers. 2.Remove 2 bolts securing remote gear change bracket to extension housing, recover washers and mounting rubbers. 3.Release remote gear change from extension housing, disconnect selector rod from selector shaft pin.Remote gear change - Type D gearbox - Remove 1.Remove 4 bolts securing remote gear change to extension housing; release remote gear change from extension housing.
MANUAL GEARBOX 8 OVERHAUL Gear change lever yoke - Type D gearbox - Remove 1.Remove and discard set screw securing yoke. 2.Move selector shaft forwards, remove yoke.Extension housing - Types A and B gearbox - Remove 1.UsingLRT-37-009, LRT-37-010and LRT-37-001/2, remove output shaft oil seal collar. 2.Remove bolt and washer securing interlock spool retainer. 3.Remove interlock spool retainer, remove and discard’O’ring.
MANUAL GEARBOX OVERHAUL9 4.Noting fitted of 2 longest bolts, remove 10 bolts securing the extension housing. 5.Place a suitable container underneath the gearbox to catch any oil spillage and remove the extension housing. 6.Remove oil filter. 7.Secure centre plate to gearcase with 2 off 8 x 35 mm slave bolts.Extension housing - Type C gearbox - Remove 1.Remove and discard self-locking nut securing selector shaft pin to selector shaft; remove pin. 2.Carefully prise speedometer pinion housing and gear out of extension housing, remove and discard’O’ring. 3.Remove bolt and washer securing interlock spool retainer. 4.Remove interlock spool retainer, remove and discard’O’ring. 5.Noting fitted position of 2 longest bolts, remove 10 bolts securing extension housing to gearcase. 6.Place a suitable container underneath the gearbox to collect any oil spillage and remove the extension housing. NOTE: Speedometer drive gear may be a tight fit on output shaft and this can prevent removal of extension housing. Insert suitable blocks of wood between extension housing and centre plate and carefully lever extension housing away until drive gear is released. 7.Remove and discard selector shaft oil seal.
MANUAL GEARBOX 10 OVERHAUL 8.Remove oil filter. 9.Secure centre plate to gearcase with 2 off 8 x 35 mm slave bolts.Extension housing - Type D gearbox - Remove 1.Remove bolt and washer securing interlock spool retainer. 2.Remove interlock spool retainer. 3.Remove and discard’O’ring - if fitted. 4.Noting fitted position of 2 longest bolts, remove 10 bolts securing extension housing to main gearcase. 5.Using a soft faced mallet, tap extension housing free from its location dowels. 6.Place a suitable container underneath the gearbox to collect any oil spillage and remove the extension housing. 7.Remove oil filter. 8.Secure centre plate to gearcase using 2 off 8 x 35 mm slave bolts.
MANUAL GEARBOX OVERHAUL11 5th and Reverse gear - Remove 1.Position gearcase as shown 2.Using a suitable two legged puller remove 5th gear layshaft support bearing track from the end of layshaft. 3.Remove staking from 5th laygear retaining nut, fit toolLRT-37-023to hold the 5th laygear. NOTE: If 5th laygear is not drilled to accept prongs of LRT-37-023, remove 13 mm (0.5 in) from each prong and locate prongs in counterbores machined in gear. The modified tool may still be used on gearboxes fitted with drilled gears. 4.Remove and discard the nut.