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 threads of blanking plug,
fit plug and tighten to 30 Nm (22 lbf.ft).
8.Smear ball pin seating with multi-purpose
grease.
9.Position ball pin seating in trunnion, secure
with a new circlip.
10.Position trunnion on selector shaft.
11.Apply Loctite 290 to threads of setscrew, fit
setscrew and tighten to 25 Nm (18 lbf.ft).
12.Fit 5th gear stop screw, fit but do not tighten
locknut.
NOTE: 5th gear stop screw adjustment is
carried out during gearbox reassembly.Gear change housing - Type B gearbox
Dismantle
1.Remove bolts retaining bias springs.
WARNING: To avoid personal injury,
restrain each spring in turn with a pair of
grips while the bolts are being removed.
2.Remove the two bias springs.
3.Remove 2 bolts securing bias spring
adjustment plate. 
						

							MANUAL GEARBOX
OVERHAUL23
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.
CAUTION: Ensure that the slots in each
bush are aligned with slots in housing.
3.Lubricate a new oil seal with gearbox oil.
4.Fit oil seal, lip side towards housing, using a
suitable mandrel.
5.Position gear lever to gear change housing
ensuring ball cross pins are located in slots in
housing and Railko bush.
6.Position bias spring adjustment plate to gear
change housing,
7.Apply Loctite 290 to threads of 2 short bias
spring adjustment plate bolts.
8.Fit bolts to secure front of bias adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9.Position bias spring to pillar ensuring longest
end of spring is against gear lever.
10.Apply Loctite 290 to threads of 2 long bias
adjustment plate bolts.
11.Restrain bias spring using a suitable pair of
grips, ensure short end of bias spring is
positioned on outside edge of bolt hole.
WARNING: Personal injury may result if
bias spring is not retained.
12.Fit bolt and washer ensuring end of bias spring
is restrained beneath washer; tighten bolt to 25
Nm (18 lbf.ft).
13.Repeat above procedures for remaining bias
spring. 
						

							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 all components.Inspection
1.Check selector rod bushes in remote housing
for wear.
NOTE: Bushes may be pressed in and out
of remote housing using a hand press and
suitable mandrel.
2.Check selector rod for wear, replace if
necessary.
3.Check anti-rattle spring for distortion and
plunger for wear; replace if necessary.
4.Check gear lever ball pin, cross pins, bushes
and selector rod yoke balls for wear and
replace if necessary. If yoke balls are worn,
remove and discard circlip, press ball and
seating out of yoke.
5.Lubricate replacement ball and seating with
multi-purpose grease and press into yoke;
secure using new circlip.
6.Check bias spring for distortion, replace if
necessary.
7.Check condition of mounting rubbers, replace
as a set if necessary.
Reassemble
1.Lubricate selector rod and bushes with multi -
purpose grease, insert rod in remote housing.
2.Lubricate gear lever ball pin and selector rod
yoke balls with multi-purpose grease.
3.Fit yoke to selector rod, fit pinch bolt and
tighten to 25 Nm (18 lbf.ft).
4.Assemble anti-rattle spring and plunger to gear
lever.
5.Fit gear lever ensuring ball pin is located in
yoke and anti-rattle spring and plunger are not
displaced.
6.Fit gear lever cap, fit bolt and tighten to 15 Nm
(11 lbf.ft).
NOTE: Do not fit bottom cover plate at this
stage.
7.Loosen bias spring adjustment bolt locknuts.
8.Fit bias spring, bridge plate liners and bridge
plates.
9.Fit bolts and countersunk screws and tighten to
25 Nm (18 lbf.ft).
NOTE: Final adjustment of bias spring is
carried out after remote gear change is
fitted to gearbox. 
						

							MANUAL GEARBOX
OVERHAUL25
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 retaining
selector fork clevis pin.
5.Remove clevis pin from selector fork, remove
and discard 2 bushes. 
						

							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
renewed as an assembly.
3.Check selector fork and clevis pin for wear.
4.Check cross shaft and end cover for wear.
5.Replace components as necessary.
Reassemble
1.Lubricate new’O’rings with gearbox oil and fit
to selector fork, position fork in housing.
2.Lubricate cross shaft with multi-purpose grease
and locate longest end of shaft in selector fork.
3.Lubricate new’O’rings with gearbox oil and fit
to end cover.
4.Position end cover on cross shaft, fit and
tighten countersunk screws.
5.Assemble ball and nylon seating to gear lever
ensuring that groove in seating is towards
cross shaft.
6.Lubricate ball and nylon seating with multi -
purpose grease and locate in cross shaft;
retain with a new circlip.
7.Position new bushes to gear lever, locate in
selector fork and fit clevis pin.
8.Fit new spring clip to retain clevis pin.
9.Position gate plate and gaiter support plate to
housing, use new gaskets.
10.Fit retaining bolts and tighten to 15 Nm (11
lbf.ft).
11.Fit gaiter. 
						

							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 of a worn tooth.
7.Replace unit if excessively worn.
Reassemble
8.Refit inner hub to sleeve.
NOTE: Hubs and sleeves have a master
spline combination and can only be
assembled one way. The sleeves are
further identified with a series of half moon
notches which clearly identify which side of the
assembly faces which gear. Ensure the slot in
the hub aligns with the centre notch on the
sleeve.
Assy Hub Sleeve Against
Gear
1st/2nd - 1 Notch 1st
2 gear
side- 2nd
3rd/4th - 3 Notches 3rd
- - 4th
5th/Rev - 5 Notches 5th
9.Fit slippers and secure with a spring each side
of the synchromesh assembly ensuring the
step on each spring locates on a different
slipper.
NOTE: 5th and reverse synchromesh hubs
have different springs which are coloured
yellow. 
						

							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. 
						

							MANUAL GEARBOX
OVERHAUL29
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. 
						

							MANUAL GEARBOX
OVERHAUL31
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.
4.Fit 1st gear synchromesh baulk rings, needle
roller bearing, 1st gear and bush on to output
shaft ensuring baulk rings locate correctly
inside selector hub.
5.UsingLRT-99-002, and a suitable mandrel
positioned on bearing inner race, press on
output shaft taper roller bearing taking care not
to disturb the position of the synchromesh
baulk rings and gears.6.Check 1st and 2nd gear end-float.
Checking 1st gear end-float
New: 0.05 - 0.20 mm (0.002 - 0.008 in)
Service limit: 0.327 mm (0.012 in)