Land Rover R380 Gearbox Overhaul 1995 3rd Edition Rover Manual

							MANUAL GEARBOX
42
OVERHAUL Gear change lever yoke - Type D gearbox - Refit
1.Position gear 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.Remote housing - Type A gearbox - Refit
1.Apply sealant, Part No. STC 3254 to mating
surfaces and fit to extension housing.
2.Position remote housing to extension housing
and gearcase ensuring rollers locate in
quadrant.
3.Fit and lightly tighten 3 bolts in positions
shown.
NOTE: Bolts are tightened when gear
change housing is fitted. 
						

							MANUAL GEARBOX
OVERHAUL43
Transfer box selector housing - Type A gearbox -
Refit
1.Smear a new gasket with grease and fit to
remote housing.
2.Position transfer box selector housing to
remote housing.
3.Fit and lightly tighten 4 bolts.
NOTE: Bolts are tightened when gear
change housing is fitted.Gear change housing - Type A gearbox - Refit
1.Smear a new gasket with grease and fit to
remote housing.
2.Position gear change housing to remote
housing ensuring gear lever ball is correctly
located.
3.Fit and lightly tighten 4 bolts.
4.Tighten remote housing, transfer box selector
housing and gear change housing bolts to 25
Nm (18 lbf.ft).
5.Adjust 5th gear stop screw. 
						

							MANUAL GEARBOX
44
OVERHAUL 5th gear stop screw adjustment - Type A
gearbox
1.Select reverse gear. While applying light
pressure to gear lever towards left, turn screw
clockwise until it contacts yoke.
2.Turn screw anti-clockwise until 25 mm (1.0 in)
of free play is felt at knob, ensure 5th gear can
be engaged.
3.Tighten locknut.
4.Check all other gears can be selected.Transfer box selector housing - Type B gearbox -
Refit
1.Smear a new gasket with grease and fit to
gearcase.
2.Position transfer box selector housing to
gearcase, fit 4 bolts and tighten to 25 Nm (18
lbf.ft). 
						

							MANUAL GEARBOX
OVERHAUL45
Gear change housing - Type B gearbox - Refit
1.Apply sealant, Part No. STC 3254 to mating
surfaces of extension housing.
2.Position gear change housing to extension
housing ensuring that gear lever passes
through centre of gear change lever yoke and
engages in the gate plate.
3.Fit bolts and tighten to 25 Nm (18 lbf.ft).Remote gear change - Type C gearbox - Refit
1.Apply lithium based grease to selector rod
yoke.
2.Position remote gear change to extension
housing ensuring selector shaft pin is located
in selector rod yoke.
3.Fit bolts, washers and mounting rubbers
securing remote gear change to extension
housing; do not tighten bolts at this stage.
4.Fit bolts, washers and mounting rubbers
securing bracket to extension housing.
5.Tighten all bolts to 25 Nm (18 lbf.ft). 
						

							MANUAL GEARBOX
46
OVERHAUL Remote gear change - Type D gearbox - Refit
1.Apply sealant, Part No. STC 3254 to mating
surfaces of extension housing and remote gear
change housing.
2.Position remote gear change housing on
extension housing. Ensure that gear lever ball
is correctly located.
3.Fit bolts and tighten to 25 Nm (18 lbf.ft).Bias spring adjustment - Type A gearbox
NOTE: The purpose of this adjustment is
to set both bolts so that the bias spring
legs apply equal pressure on both ends of
the gear lever cross pin when third or fourth gear
is engaged. This will ensure that when the lever
is in neutral, the gear change mechanism is
automatically aligned for third or fourth gear.
1.Select third or fourth gear.
2.Adjust the two adjusting screws until both legs
of the spring are approximately 0.5 mm (0.02
in) clear of the cross pin in the gear lever.
3.Apply a light load to the gear lever in a left
hand direction and adjust the right hand
adjusting screw downward until the right hand
spring leg just makes contact with the cross
pin.
4.Repeat the same procedure for the left hand
adjusting screw.
5.Lower both adjusting screws equal amounts
until the radial play is just eliminated.
6.Tighten locknuts.
7.Return gear lever to neutral position and rock
across the gate several times. The gear lever
should return to the third and fourth gate. 
						

							MANUAL GEARBOX
OVERHAUL47
Bias spring adjustment - Type B gearbox
1.Loosen bias adjustment plate bolts. Select
fourth gear and move lever fully to the right.
2.Tighten bias adjustment plate bolts to 25 Nm
(18 lbf.ft).
3.Check adjustment is correct by selecting third
and fourth gears.
4.Fit sealing rubber to gear change housing, fit
housing.
5.Apply Loctite 290 to threads of securing
screws, fit screws and tighten to 8 Nm (6 lbf.ft)Bias spring adjustment - Type C gearbox
NOTE: The purpose of this adjustment is
to ensure that when bias spring is
correctly adjusted, the gear change
mechanism is automatically aligned for 3rd or
4th gear selection when gear lever is in neutral.
1.Adjust both bias spring adjustment bolts until a
clearance of 0.5 mm (0.02 in) exists between
both legs of bias spring and gear lever cross
pin.
2.Apply a light load to move gear lever to the left
and adjust right hand bolt until right hand leg of
bias spring just contacts gear lever cross pin.
3.Move gear lever to the right and adjust left
hand bolt.
4.Check that with gear lever moved fully to the
left and right, spring legs just contact gear lever
cross pin.
5.Select neutral then rock gear lever across the
gate; when released, lever should return to
3rd/4th position.
6.Tighten adjusting bolt locknuts. 
						

							MANUAL GEARBOX
48
OVERHAUL Clutch housing - Type A gearbox - Refit
1.Position clutch housing to gearbox.
2.Fit securing bolts.
NOTE: The 12 x 45 mm bolts must be fitted
through locating dowels.
3.Tighten bolts by diagonal selection to 72 Nm
(53 lbf.ft).
4.Fit pivot post, fit and tighten bolts.
5.Apply lithium based grease to pivot post, pads
and push rod.
6.Position pads to clutch release lever, fit release
bearing.
7.Fit new clips to retain pads.
NOTE: Clips may become displaced in
service with no loss of performance.
8.Fit release lever.
9.Apply lithium based grease to splines of input
shaft.Clutch housing - Type B gearbox - Refit
1.Position clutch housing to gearbox.
2.Fit securing bolts.
NOTE: The 12 x 45 mm bolts must be fitted
through locating dowels.
3.Tighten bolts by diagonal selection to 72 Nm
(53 lbf.ft).
4.Apply lithium based grease to pivot post,
release lever, socket and push rod.
5.Fit a new’C’clip to pivot post, fit post.
6.Fit spring clip to release lever, fit but do not
tighten bolt. 
						

							MANUAL GEARBOX
OVERHAUL49
7.Position release lever to pivot post ensuring
spring clip is located behind’C’clip; tighten
bolt.
8.Fit clutch release bearing and retain using new
clips.
NOTE: Clips may become displaced in
service with no loss of performance.
9.Apply lithium based grease to splines of input
shaft.Clutch housing - Type C gearbox - Refit
1.Position clutch housing to gearbox.
2.Fit securing bolts.
NOTE: The 2 longest bolts must be fitted
at locating dowel positions.
3.Tighten bolts by diagonal selection to 72 Nm
(53 lbf.ft).
4.Apply lithium based grease to pivot post.
5.Fit release lever and clutch release bearing.
6.Apply lithium based grease to splines of input
shaft. 
						

							MANUAL GEARBOX
50
OVERHAUL Adaptor housing - Type D gearbox - Refit
1.Position adaptor housing to gearbox.
2.Fit securing bolts.
NOTE: The two longest bolts must be
fitted at locating dowel positions.
3.Tighten bolts by diagonal selection to 72 Nm
(53 lbf.ft).
4.Apply lithium based grease to pivot post.
5.Fit pivot post, fit 2 bolts and tighten to 25 Nm
(18 lbf.ft).
6.Apply lithium based grease to splines of input
shaft.