Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual

							MANUAL GEARBOX
12
OVERHAUL 5.Remove thrust collar segments, retaining ring
and segments, drift out the roll pin.
6.Later gearboxes:Remove split washer
securing 5th laygear to shaft.
7.Remove 5th laygear.
8.Remove output shaft rear support bearing track
using toolsLRT-37-009, LRT-37-010and
LRT-37-001/2.
9.Remove output shaft 5th gear with
synchromesh baulk ring.
10.Remove output shaft 5th gear split needle
roller bearing.
11.Remove and discard circlip securing 5th gear
synchromesh hub.
12.Pull selector shaft out of gearcase until selector
spool can be rotated clear of fork. Remove 5th
and reverse synchromesh hub assembly
complete with fork and spool.
13.Remove output shaft reverse gear complete
with needle roller bearing and bush noting
selective spacer between reverse gear bush
and centre plate bearing.
14.Remove layshaft reverse gear.
15.Remove centre plate Torx detent plug, spring
and ball.
16.Remove 2 bolts securing spool retainer,
remove retainer; remove and discard’O’ring -
if fitted. 
						

							MANUAL GEARBOX
OVERHAUL13
Output shaft and layshaft - Remove
1.Remove slave bolts securing centre plate.
2.Align selector shaft pin with slot in centre plate
and using wooden blocks and hide mallet,
drive off centre plate; collect lower detent ball
and spring.
3.Remove bearing tracks and shims from centre
plate.
4.Remove layshaft, output shaft and selector
shaft from casing as an assembly.
5.Remove input shaft, and 4th gear baulk ring. (If
not already removed with output shaft). 
						

							MANUAL GEARBOX
14
OVERHAUL Output shaft - Dismantle
1.UsingLRT-99-002and support bars under 1st
gear, press output shaft support bearing from
output shaft.
2.Remove 1st gear, bush, needle bearing and
synchromesh baulk rings.
3.Remove 1st/2nd gear synchromesh selector
hub, 2nd gear synchromesh baulk rings,
second gear and needle bearing. 
						

							MANUAL GEARBOX
OVERHAUL15
4.Invert output shaft and usingLRT-99-002and
support bars under 3rd gear, press off pilot
bearing.
5.Remove spacer, 3rd/4th gear synchromesh
selector hub, synchromesh baulk rings, 3rd
gear and needle bearing.Gearcase
Degrease and clean all components. Inspect casing
for damage, cracks and stripped threads.
1.Fit oil filer/level plug.
CAUTION: Attach a suitable label
indicating gearbox oil is drained.
2.Fit new sealing washer to drain plug, fit plug
and tighten to 50 Nm (37 lbf.ft). 
						

							MANUAL GEARBOX
16
OVERHAUL Front Cover - Remove
NOTE: Early type front cover illustrated.
1.Remove 6 bolts securing front cover to
gearcase, remove cover.Front Cover - Early Type - Dismantle
NOTE: Early type front cover can be
identified by the lug on each side of the
cover.
1.Remove input shaft bearing track from front
cover. Check that spring clips are intact.
2.Remove and discard oil seal from front cover.
3.Remove layshaft bearing track from front
cover. 
						

							MANUAL GEARBOX
OVERHAUL17
Front cover - Later Type - Dismantle
NOTE: Later type front covers have one
lug only on the side of the cover and
layshaft bearing track is pressed into the
cover.
1.Remove layshaft bearing track from front
cover.
2.Remove input shaft bearing track from front
cover, remove and discard oil seal .Centre plate - Dismantle
1.Remove bearing tracks and shims.
2.Check selector rail bore for wear.3.Remove 2 bolts securing splash shield.
4.Press out reverse idler gear shaft using
suitable press and check shaft for wear.
5.Remove idler gear, needle bearing and spacer
and check for wear and damage.
6.Check centre plate detent balls for wear and
springs for distortion, replace as necessary.
7.Check that threads of detent plug are not
damaged. 
						

							MANUAL GEARBOX
18
OVERHAUL Extension housings - Overhaul
Types A and B gearbox
1.Examine for damage to threads and machined
faces.
NOTE: Types A and B gearbox extension
housing shown.
2.Remove 3 screws and remove oil pump,
remove and discard’O’ring.
3.Remove oil pick-up pipe and check for
obstruction.
4.Drift out layshaft support bearing.
5.Remove and discard output shaft rear oil seal.
6.Drift out output shaft support bearing and oil
pick up ring.
7.Unscrew reverse inhibitor shaft.
8.Remove reverse inhibitor cam and spring.
9.Remove reverse light switch and sealing
washer, discard sealing washer.
10.Remove gate plate.
11.Check all components for wear and renew as
necessary.Type C gearbox - As for A and B Types and
including the following:
12.Recover speedometer drive gear and spacer.
13.Check speedometer drive gear for wear and
damage, renew if necessary.
14.Check speedometer pinion for wear and
damage. Check that scrolling on shaft is clear;
renew pinion and shaft if necessary.
15.Check slots in interlock spool for wear, renew
interlock spool if necessary.
Type C and D gearboxes
CAUTION: The output shaft rear oil seal
fitted to Type C and D extension housings
is different to Types A and B. When
levering out seal, take care not to damage the
seal location surfaces.
NOTE: Type D gearbox extension housing
shown.
1.Remove and discard output shaft oil seal.
2.Remove 3 screws and remove oil pump,
remove and discard’O’ring. 
						

							MANUAL GEARBOX
OVERHAUL19
Reassemble
1.Lubricate oil pump recess with gearbox oil.
2.Lubricate new’O’ring with gearbox oil and fit
to oil pump.
3.Locate oil pump into extension housing
ensuring that word’TOP’on pump is towards
top of housing.
4.Align fixing screw holes and tap pump lightly at
edges until it is fully in housing, fit screws and
tighten to 6 Nm (4.5 lbf.ft).
CAUTION: Do not pull pump into housing
by tightening screws.
5.Fit new output shaft support bearing.
6.Lubricate a new output shaft rear oil seal with
gearbox oil and fit seal using toolLRT-37-014.
7.Fit new layshaft support bearing.
8.Fit new oil pick-up ring ensuring that tag is
aligned with centre of drain slot.
9.Examine gate plate and renew if worn or
damaged.
10.Fit gate plate, fit bolts and tighten to 15 Nm (11
lbf.ft).
11.Fit reverse light switch and new sealing
washer. Tighten to 24 Nm (17 lbf.ft).
12.Apply Loctite 290 to threads of reverse inhibitor
shaft, position shaft and fit reverse inhibitor
cam and spring.
13.Tighten reverse inhibitor shaft.
14.Refit oil pick-up pipe, bend uppermost.Gear change/selector housings - Overhaul
Gear change housing - Type A gearbox
Dismantle
1.Using a suitable piece of tubing, release both
ends of bias spring from ball pins.
2.Slacken locknuts and remove bias spring
adjusting screws.
3.Drift out roll pin, remove bias spring. 
						

							MANUAL GEARBOX
20
OVERHAUL
4.Remove extension from lower gear lever.
5.Remove bolt and special washer securing
lower gear lever.
6.Carefully withdraw lower gear lever from
housing ensuring that spring loaded nylon pad
is retained during removal.
WARNING: Personal injury may result if
pad is not retained.
7.Release nylon pad, recover spring.
8.Clean all components.Inspection
1.Check lower gear lever ball pin for wear,
replace if necessary.
CAUTION: If lower gear lever is to be
replaced then ball pin seating, located in
remote housing should also be replaced.
2.Check nylon pad and spring for wear and
damage, replace if necessary.
3.Check bias spring roll pin for damage, replace
if necessary.
Reassemble
1.Smear ball pin with multi-purpose grease and
fit spring and nylon pad.
2.Depress nylon pad against spring pressure,
position lower gear lever in housing.
CAUTION: Ensure nylon pad is facing
away from bias spring location.
3.Fit lower gear lever retaining bolt and special
washer, tighten bolt to 15 Nm (11 lbf.ft).
4.Fit extension to lower gear lever.
5.Position roll pin and bias spring to housing, fit
roll pin.
6.Fit bias spring adjusting screws and locknuts.
7.Using a suitable piece of tubing locate both
ends of bias spring over ball pins.
NOTE: Do not adjust bias spring at this
stage. 
						

							MANUAL GEARBOX
OVERHAUL21
Remote housing - Type A gearbox
Dismantle
1.Remove setscrew securing trunnion to selector
shaft, remove trunnion.
2.Remove and discard circlip securing ball pin
seating to trunnion, remove seating.
3.Loosen locknut, remove 5th gear stop screw.
4.Remove blanking plug from end of remote
housing.
5.Remove setscrew securing quadrant to
selector shaft, remove quadrant.
NOTE: Early gearboxes: Quadrant is
secured by a roll pin.
6.Remove selector shaft from remote housing,
remove and discard’O’ring.
7.Remove and discard circlip retaining rollers
and pin to quadrant.
8.Remove pin, recover rollers.
9.Clean all components.
Inspection
1.Check selector shaft and bore in remote
housing for wear.
2.Check quadrant rollers and pin for wear.
3.Check ball pin seating for wear.
4.Replace worn components as necessary.