LAND ROVER R380 GEARBOX OVERHAUL MANUAL – 3rd Edition (LRL 0003ENG)

This manual contains procedures for overhaul of the R380 gearbox on the bench with the clutch and, if applicable, the transfer box removed. For all other information regarding Adjustments, Removal of oil seals, clutch, transfer box and gearbox unit, consult the appropriate Repair Manual for the model concerned.

This Overhaul Manual contains information applicable to the following models:

• New Range Rover
• Range Rover Classic 1995 Models on
• Discovery 1995 Models on
• Defender 1995 Models on
• Discovery 2

How to use this manual

To assist in the use of this manual the section title is given at the top and the relevant sub – section is given at the bottom of each page.

This manual is divided into 5 sections, Data, Torque Settings, Service Tools, Description and finally, Overhaul.To assist filing of revised information each sub – section is numbered from page 1. The individual overhaul items are to be followed in the sequence in which they appear. Items numbered in the illustrations are referred to in the text.

Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool in use. Operations also include reference to wear limits, relevant data, torque figures, and specialist information and useful assembly details.

DESCRIPTION

The R380 5 speed all synchromesh gearbox comprises an input shaft, output shaft, layshaft and reverse idler shaft. Gearbox casings consist of a front cover, gearcase, centre plate and extension housing, all casings are located by dowels and sealed. Selector forks for 1st/2nd and 3rd/4th gears are located on a single selector shaft inside the main gearcase whilst the selector fork for fifth and reverse gear is located on the same selector shaft inside the extension housing. The input shaft, output shaft and layshaft are supported by taper roller bearings with all gears running on caged needle roller bearings. Output shaft and layshaft bearings end float is controlled by selective thrust washers located in the centre plate. Lubrication is by an oil pump located in the extension housing which directs oil via internal drillings in the output shaft to lubricate the components.

CONTENTS

• DATA
  • GENERAL DATA
• TORQUE WRENCH SETTING
  • TORQUE WRENCH SETTINGS
• SERVICE TOOLS
  • SERVICE TOOLS
• DESCRIPTION AND OPERATION
  • DESCRIPTION
  • GEARBOX COMPONENTS – GEARS AND SHAFTS
  • GEARBOX CASINGS
  • GEAR CHANGE HOUSING – TYPE A GEARBOX
  • GEAR CHANGE HOUSING – TYPE B GEARBOX
  • REMOTE GEAR CHANGE HOUSING – TYPE C GEARBOX
  • TRANSFER BOX SELECTOR HOUSING – TYPE A GEARBOX
• OVERHAUL
  • GEARBOX DISMANTLE
  • Clutch housing – Type A gearbox – Remove
  • Clutch housing – Type B gearbox – Remove
  • Clutch housing – Type C gearbox – Remove
  • Clutch housing – Type D gearbox – Remove
  • Gear change/selector housings – Type A gearbox – Remove
  • Remote housing – Type A gearbox – Remove
  • Gear change/selector housings – Type B gearbox – Remove
  • Selector quadrant – Type A gearbox – Remove
  • Gear change lever yoke – Type B gearbox – Remove
  • Remote gear change – Type C gearbox – Remove
  • Remote gear change – Type D gearbox – Remove
  • Gear change lever yoke – Type D gearbox – Remove
  • Extension housing – Types A and B gearbox – Remove
  • Extension housing – Type C gearbox – Remove
  • Extension housing – Type D gearbox – Remove
  • 5th and Reverse gear – Remove
  • Output shaft and layshaft – Remove
  • Output shaft – Dismantle
  • Gearcase
  • Front Cover – Remove
  • Front Cover – Early type – Dismantle
  • Front Cover – Later type – Dismantle
  • Centre plate – Dismantle
  • Extension housings – Overhaul
  • Gear change/selector housings – Overhaul
  • Synchromesh assemblies – Overhaul
  • Checking baulk ring clearances
  • Input shaft – Overhaul
  • Output shaft – Inspection
  • Layshaft – Overhaul
  • Output shaft – Reassemble
  • Reverse idler gear and centre plate – Reassemble.
  • Selectors – Inspection
  • Selectors – Reassemble
  • GEARBOX REASSEMBLE
  • Output shaft and layshaft end float
  • Shimming
  • Assembling output shaft and layshaft to centre plate
  • Reverse and 5th gear – Reassemble
  • Extension housing – Type A and B Gearbox – Refit
  • Extension housing – Type C gearbox – Refit
  • Extension housing – Type D gearbox – Refit
  • Selector quadrant – Type A gearbox – Refit
  • Gear change lever yoke – Type B gearbox – Refit
  • Gear change lever yoke – Type D gearbox – Refit
  • Remote housing – Type A gearbox – Refit
  • Transfer box selector housing – Type A gearbox – Refit
  • Gear change housing – Type A gearbox – Refit
  • 5th gear stop screw adjustment – Type A gearbox
  • Transfer box selector housing – Type B gearbox – Refit
  • Gear change housing – Type B gearbox – Refit
  • Remote gear change – Type C gearbox – Refit
  • Remote gear change – Type D gearbox – Refit
  • Bias spring adjustment – Type A gearbox
  • Bias spring adjustment – Type B gearbox
  • Bias spring adjustment – Type C gearbox
  • Clutch housing – Type A gearbox – Refit
  • Clutch housing – Type B gearbox – Refit
  • Clutch housing – Type C gearbox – Refit
  • Adaptor housing – Type D gearbox – Refit

Language: English
Format: PDF
Pages: 79

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