Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual

							MANUAL GEARBOX
32
OVERHAUL
Checking 2nd gear end-float
New: 0.04 - 0.21 mm (0.0016 - 0.008 in)
Service limit: 0.337 mm (0.013 in)
7.Invert output shaft in vice and fit 3rd gear
needle roller bearing, third gear and
synchromesh baulk rings.
8.Assemble 3rd/4th gear synchromesh selector
hub, noting 3rd speed side markings, on to
output shaft splines taking care to locate the
baulk rings into recesses in the selector hub.
9.Fit spacer.
10.UsingLRT-99-002and a suitable mandrel
positioned on bearing inner race, press on new
pilot bearing.Check end float of 3rd gear.
Checking 3rd gear end-float
New: 0.11 - 0.21 mm (0.004 - 0.008 in)
Service limit: 0.337 mm (0.013 in) 
						

							MANUAL GEARBOX
OVERHAUL33
Reverse idler gear and centre plate - Reassemble
1.Examine components for wear and damage.
2.Assemble reverse idler gear needle roller
bearing, idler gear, spacer and shaft and using
suitable tool, press into centre plate.
3.Using feeler gauges, check clearance between
reverse idler gear and shaft flange, fit a thicker
or thinner spacer if necessary in order to
achieve correct clearance.
New clearance:
0.04 - 0.38 mm (0.0016in - 0.015 in)
Service limit:
0.38 mm (0.015 in)
4.Fit splash shield, fit bolts and tighten to 8 Nm
(6 lbf.ft).
CAUTION: Do not fit detent balls or
springs at this stage.Selectors - Inspection
1.Examine selector rail and pins for wear and
damage.
2.Examine selector forks for wear and damage.
NOTE: The selector rail and fork is only
supplied as a complete assembly.
3.Examine interlock spools for wear and
damage. 
						

							MANUAL GEARBOX
34
OVERHAUL Selectors - Reassemble
1.Rest 1st/2nd fork and shaft assembly on bench
and locate pin in jaw of fork.
2.Fit interlock spool and 3rd/4th fork and engage
spool in jaw of fork.
3.Slide spool and fork towards 1st/2nd selector
until slot in spool locates over pin keeping the
spool engaged in 3rd/4th fork jaw.GEARBOX REASSEMBLE
Output shaft and layshaft end float
NOTE: The end float setting for both the
output shaft and the layshaft has to be
determined before the gearbox can be
reassembled. This is achieved by clamping the
output shaft and layshaft separately between the
centre plate and main casing and measuring the
movement of each shaft with a dial test indicator.
Shimming
1.Fit new bearing tracks to front cover.
CAUTION: Ensure input shaft bearing
track is correct for type of front cover
fitted. Early covers having a lug each side
of cover, bearing track is retained with a spring
clip. Later covers having a lug on one side of
cover, press bearing track into cover using a
suitable mandrel.
2.Fit front cover to gearcase without oil seal.
3.Clamp gearcase in vice with front cover
downwards.
4.Fit input shaft.
CAUTION: Do not fit 4th gear baulk ring.
5.Fit output shaft assembly to input shaft.
6.Fit output shaft bearing shim and track to
centre plate. 
						

							MANUAL GEARBOX
OVERHAUL35
7.Fit centre plate and bolt down using 8 off 8 x
35 mm slave bolts.
CAUTION: Do not fit detent ball or spring
at this stage.
8.Fit large ball bearing to rear of output shaft.
9.Mount dial test indicator.
10.Rotate output shaft to settle bearings.
11.Lift output shaft and note DTI reading.
The end float setting for the output shaft and
layshaft is:-
Early gearboxes without suffix K added to serial
number:
New: 0.01 - 0.06 mm (0.0004 - 0.0024 in)
Service limit: 0.06 mm (0.0024 in)
Later gearboxes with suffix K added to serial
number:
New: 0.00 - 0.05 mm (0.00 - 0.002 in)
Service limit: 0.05 mm (0.002 in)
Shims to make up the required clearances are
placed under the respective bearing tracks in the
centre plate.
12.Dismantle and substitute shims if reading
incorrect.
13.Remove output shaft assembly and repeat
procedure for layshaft.
14.Remove centre plate, layshaft and output shaft.
15.Remove front cover.
16.Remove input shaft bearing track from front
cover, retain track with cover.Assembling output shaft and layshaft to centre
plate
1.Secure centre plate to suitable workstand.
2.Fit selected shims and bearing tracks.
3.Fit lower detent ball and spring, use a dummy
bar to temporarily hold the ball in place.
4.Check both synchromesh units are in neutral
and fit selector shaft assembly to output shaft.
5.Fit output shaft and selectors as complete unit
to centre plate aligning pin with slot in plate.
CAUTION: Take care that as dummy shaft
is removed, detent spring and ball are not
displaced.
6.Fit 4th gear synchromesh baulk ring. 
						

							MANUAL GEARBOX
36
OVERHAUL
7.Fit layshaft whilst lifting output shaft to clear
layshaft rear bearing.
8.Lubricate pilot bearing with gearbox oil and fit
input shaft.
NOTE: Early type front cover illustrated.
9.Fit new oil seal to front cover. Ensure seal is
fitted down to shoulder. Apply sealant, Part No.
STC 3254 to front cover as shown.
CAUTION: Oil seal must be fitted dry.
10.Fit input and layshaft bearing tracks in front
cover.
11.Apply Loctite 290 to threads of front cover
bolts, fit bolts and tighten by diagonal selection
to 25 Nm (18 lbf.ft).
12.Apply sealant, Part No. STC 3254 to centre
plate and fit main casing to centre plate.
13.Bolt casing and centre plate together using 2
off 8 x 35 slave bolts.
14.Lubricate a new’O’ring with gearbox oil and fit
to interlock spool retainer.
15.Fit interlock spool retainer, fit bolt and tighten
to 8 Nm (6 lbf.ft).
16.Remove casing from stand and clamp in vice. 
						

							MANUAL GEARBOX
OVERHAUL37
Reverse and 5th gear - Reassemble
1.Fit output shaft reverse gear selective washer,
bush and needle bearing.
2.Fit output shaft reverse gear and synchromesh
baulk ring.
3.Fit layshaft reverse gear.
4.Assemble selector spool, selector fork and
reverse/5th gear synchromesh hub. Fit as one
assembly to output shaft splines and selector
shaft.
CAUTION: Ensure synchromesh baulk
ring locates inside hub.
5.Fit new circlip.
NOTE: The fit of the circlip is controlled by
the selective washer behind the reverse
gear. Adjust to 0.005 - 0.055 mm (0.0002 -
0.002 in).6.Fit 5th gear split needle bearing.
7.Fit 5th gear and 5th gear synchromesh baulk
ring to output shaft, fit layshaft 5th gear.
8.Later gearboxes:Fit split washer to retain
layshaft 5th gear.
NOTE: Bevelled side of washer must face
towards gear.
9.Fit new output shaft thrust collar roll pin. Locate
5th gear thrust segments and retaining ring. 
						

							MANUAL GEARBOX
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OVERHAUL
10.UsingLRT-37-023to hold layshaft 5th gear, fit
a new layshaft stake nut and tighten to 220 Nm
(162 lbf.ft).
11.Stake layshaft 5th gear nut.
12.UsingLRT-37-015andLRT-37-021press
output shaft rear support bearing track to collar
on output shaft.
13.Apply small amount of heat and fit layshaft rear
support bearing.
14.Fit centre plate detent ball and spring.
15.Apply Loctite 290 to threads of detent plug, fit
plug and tighten to 25 Nm (18 lbf.ft).
16.Move selector shaft and check that detent balls
can be felt to engage in detent. 
						

							MANUAL GEARBOX
OVERHAUL39
Extension housing - Type A and B Gearbox -
Refit
1.Remove slave bolts from centre plate.
2.Fit oil filter.
3.Apply sealant, Part No. STC 3254 to mating
surfaces and fit extension housing ensuring oil
pipe locates in filter and drive locates in oil
pump.
CAUTION: Do not use force, if necessary,
remove extension housing and re - align
oil pump drive.
4.Apply Loctite 290 to threads of extension
housing securing bolts, fit bolts and tighten by
diagonal selection to 25 Nm (18 lbf.ft).
5.Lubricate a new’O’ring with gearbox oil and fit
to extension housing interlock spool retainer.
Fit retainer, fit bolt and washer and tighten bolt
to 8 Nm (6 lbf.ft).
6.UsingLRT-37-015andLRT-37-021press on
output shaft oil seal collar, narrow portion of
collar leading. 
						

							MANUAL GEARBOX
40
OVERHAUL Extension housing - Type C gearbox - Refit
1.Lubricate a new selector shaft oil seal with
gearbox oil and fit seal.
2.Remove slave bolts from centre plate.
3.Fit oil filter.
4.Fit spacer
5.Position speedometer drive gear on output
shaft splines.
6.Using a round nosed punch, carefully tap
speedometer drive gear into position.
7.Apply sealant, Part No. STC 3254 to mating
surfaces.
8.Fit extension housing ensuring oil pipe locates
in filter and drive locates in oil pump.
CAUTION: Do not use force, if necessary,
remove extension housing and re-align oil
pump drive.
9.Apply Loctite 290 to threads of extension
housing bolts, fit bolts and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
10.Lubricate a new’O’ring with gearbox oil and fit
to speedometer pinion housing.
11.Lubricate speedometer pinion with silicone
grease.
12.Fit speedometer pinion housing ensuring teeth
of pinion mesh with those of driven gear.
13.Lubricate a new’O’ring with gearbox oil and fit
to extension housing interlock spool retainer.
Fit retainer, fit bolt and washer and tighten bolt
to 8 Nm (6 lbf.ft).
14.Fit selector shaft pin to selector shaft, fit and
tighten a new self-locking nut.Extension housing - Type D gearbox - Refit
1.Remove slave bolts from centre plate.
2.Fit oil filter.
3.Apply sealant, Part No. STC 3254 to mating
surfaces and fit extension housing. Ensure that
oil pipe locates in filter and that drive locates in
oil pump.
CAUTION: Do not use force. If necessary,
remove extension housing and re-align oil
pump drive.
4.Apply Loctite 290 to threads of extension
housing retaining bolts, fit bolts and tighten by
diagonal selection to 25 Nm (18 lbf.ft).
5.Lubricate a new’O’ring with gearbox oil and fit
to interlock spool retainer. Fit retainer, fit bolt
and washer and tighten bolt to 8 Nm (6 lbf.ft). 
						

							MANUAL GEARBOX
OVERHAUL41
Selector quadrant - Type A gearbox - Refit
1.Position selector quadrant to selector shaft.
2.Apply Loctite 290 to threads of a new setscrew.
Fit and tighten screw to 25 Nm (18 lbf.ft).
CAUTION: Ensure end of setscrew locates
in hole in selector shaft.
3.Move selector shaft to neutral position.Gear change lever yoke - Type B gearbox - Refit
1.Position gear change lever yoke on selector
shaft with ball facing towards output shaft.
2.Apply Loctite 290 to threads of a new setscrew,
fit and tighten screw to 25 Nm (18 lbf.ft).
CAUTION: Ensure end of setscrew locates
in hole in selector shaft.