r380e - Land Rover

1 R380 GEARBOXOVERHAULMANUALThisOverhaulManualc ontainsinformationapplicableto 2ndEditionPublishedbyRoverTechnicalCommu nication 1996 RoverGroupLimitedINTRODUCTIONINTRODUCTIO N1 INTRODUCTIONH owtousethismanualToassistin theuseof thismanualthesectiontitleisgivenat thetopandtherelevantsub- sectionisgivenat thebottomof theR380gearboxonthebenchwiththeclutchand ,ifapplicable, ,Removalof oilseals,clutch,transferboxandgearboxuni t, dividedinto5 sections,Data,TorqueSettings,ServiceTool s,Descriptionandfinally, revisedinformationeachsub- sectionis befollowedinthesequencein theillustrationsarereferredto in ServiceToolnumbersandtheassociatedillust rationdepictsthetoolin ,relevantdata,torquefigures, ,CAUTIONSandNoteshavethefollowingmeaning s.

2 Thismanualdonotincludereferenceto isessentialthatworkis inspectedandtestedaftercompletionandif necessary,a roadtestof thevehicleis carriedout, is particularlydrawnto thefollowingpointsconcerningrepairsandth efittingof thecarmaybeimpairedif certainterritories,legislationprohibitst hefittingof partsnotto themanufacturer ,wherespecified, theefficiencyof a lockingdeviceisimpairedduringremovalit thevehicleWarrantymaybeinvalidatedbythef ittingof improvethespecification,designandproduct ionof ensuretheaccuracyof thisManual,it shouldnotberegardedasaninfallibleguideto currentspecificationsof Rover /LandRoverandhavenoauthorityto thismanualcoveroverhaulof theR380gearboxfittedto a rangeof vehiclesandassuch,certaindifferencesexis tbetweengearboxes,particularlyin respectof theextensionhousings, is importantthereforethatbeforestartingwork ,thegearboxto thegearboxcasingandreferringtothefollowi ngtablewhichlistsfourtypesof gearbox ,A,B,C andD thismanuallisttheapplicablegearboxtypere ferredto andit isimportantthattherelevantoperationis gearboxprefixes:- 50A;51A;56A.

3 58A;60A;61A;TypeB gearboxprefixes:- 53A;55A;63 ATypeC gearboxprefix:- 18 ATypeD gearboxprefixes:- 64A;65 AMANUALGEARBOXGENERALDATA1 REVISED:12 ( ) ( ) ( ) ( ) ( ) ( ) ( )Adjust5th- reversehub- shimto ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( )LubricantsATFM2C33F or GCapacitiesOilcoolerfitted= HylosilRTV102 AvailablethroughUnipartBoltsandfillerplu g- Loctite270orMarstonBentleyHylogrip640(st udlock)MANUALGEARBOXTORQUEWRENCHSETTINGS 1 REVISED:12/96 TORQUEWRENCHSETTINGSO ilpumpto extensioncase6 NmAttachmentplateto gearcase8 NmAttachmentplateto remotehousing8 NmBottomcoverto clutchhousing8 NmBreatherbaffle8 NmClipto clutchreleaselever8 NmCoverto gearchangehousing8 NmSpoolretainerto gearcase8 NmTorsionspringlocknut- adjustingscrew8 NmScrew- gearleverretention8 NmBreather15 NmGearleverretainerbolt15 NmReverseinhibitorshaft16 NmReverselightswitch24 NmTransferboxto remotehousingbolts25 NmBiasadjustmentplatebolts25 NmSelectorquadrantsetscrew25 NmGearchangeleveryokesetscrew25

4 NmAdjustmentplateto gearchangehousing25 NmExtensioncaseto gearcase25 NmFrontcoverto gearcase25 NmGearchangehousingto extensioncase25 NmGearleverhousingto remotehousing25 NmGuide- clutchreleasesleeveto bellhousing25 NmMountingbracket25 NmPivotclutchleverto bellhousing25 NmPivotplateto bellhousing25 NmPlug- detentballandspring25 NmPlungerhousingto gearchangehousing25 NmRemoteselectorhousingto extensioncase25 NmSlavecylinderto clutchhousing25 NmUppergearleverassemblyto lowergearlever25 NmYoketo selectorshaft25 NmFillerplug30 NmOillevelplug30 NmOildrainplug50 NmClutchhousingto gearbox72 NmOutputflangebolt90Nm5thgearlayshaftsta kenut220 NmMANUALGEARBOXSERVICETOOLS1 SERVICETOOLSNOTE:Wheretheuseofspecialtoo lsis specified, , , ,LondonRoad,Daventry,Northants.

5 12/96 DESCRIPTIONTheR3805 speedallsynchromeshgearboxcomprisesaninp utshaft,outputshaft, a frontcover,gearcase,centreplateandextens ionhousing, singleselectorshaftinsidethemaingearcase whilsttheselectorforkforfifthandreverseg earis , controlledbyselectivethrustwasherslocate din byanoilpumplocatedin theextensionhousingwhichdirectsoilviaint ernaldrillingsin theoutputshaftto (mainshaft& layshaftendfloat) (5thgear/reversehub)12/96 MANUALGEARBOX2 DESCRIPTIONANDOPERATIONREVISED:12/96 MANUALGEARBOXDESCRIPTIONANDOPERATION3 REVISED:12/96 GEARBOXCOMPONENTS- TypeA TypeC (outputshaft) :12 TypesA andB O O O TypeC TypeC TypeC TypeC TypeC TypeC TypeC TypeC TypeC gearbox41.

6 O ring- TypeC TypeC TypeC TypeC TypeC TypeC TypeD TypeD gearboxMANUALGEARBOX6 DESCRIPTIONANDOPERATIONMANUALGEARBOXDESC RIPTIONANDOPERATION7 GEARCHANGEHOUSING- TYPEA O TYPEB O ringsMANUALGEARBOXOVERHAUL1 GEARBOXDISMANTLES ervicerepairno- TypeA gearbox - fitted:removeanddiscardclipsretainingclu tchreleasebearingpads,removebearingandcl utchreleaselever, boltssecuringreleaseleverpivotpost, boltssecuringclutchhousingtogearbox, TypeB gearbox - clutchreleaselever, C clipfromreleaseleverpivotpost, boltssecuringclutchhousingtogearbox, TypeC gearbox - , boltssecuringclutchhousingtogearbox, :2 TypeD gearbox - RemoveNOTE.

7 TypeD gearboxeshavea (containingtheclutchmechanism) TypeA gearbox - boltssecuringgearchangehousing, boltssecuringtransferboxselectorhousing, TypeA gearbox - ,remove3 boltssecuringremotehousing, TypeB gearbox - Torxscrewssecuringgearchangehousingcover ,removecover; boltssecuringtransferboxselectorhousing, ,remove3 boltssecuringgearchangehousing, TypeA gearbox - , TypeB , TypeC gearbox - mountingrubbersandwashers,Rremove2 boltssecuringremotegearchangeto extensionhousing, boltssecuringremotegearchangebracketto extensionhousing, , TypeD gearbox - boltssecuringremotegearchangeto TypeD TypesA andB 12mmboltintotheendof suitablecontainerunderneaththeboxto gearcasingwith2 bolts8 x TypeC gearbox - selectorshaft.

8 Extensionhousing,removeanddiscard O ,removeanddiscard O ,remove10boltssecuringextensionhousingto softfacedmallet,tapextensionhousingto freeit gearcasewith2 bolts8x TypeD gearbox - ,notingpositionof suitablecontainerunderneaththeboxto softfacedmallet, suitabletwoleggedpullerremove5thgearlays haftsupportbearingtrackfromtheendof holdthe5thlaygear, ,retainingringandsegments, :Removesplitwashersecuring5thlaygearto , boltssecuringspoolretainer, slave centreplateandusingwoodenblocksandhidema llet, , , ,and4thgearbaulkring.(Ifnotalreadyremove dwithmainshaft).

9 Mainshaft- , , ,2ndgearsynchromeshbaulkrings, , ,3rd/4thgearsynchromeshselectorhub,synch romeshbaulkrings, , newsealat , , TypesA andB :TypesA andB gearbox - As forA andB ,renewif clear;renewpinionandshaftif 5thgearspoolguideforwear,renewspoolguide if andD gearboxesCAUTION:Therearmainshaftoilseal fittedtoTypeC andD extensionhousingsis differenttoTypesA , :TypeD , lightcoatof O :Ensure TOP (Aligntagwithcentreofdrainslot). , OverhaulGearchangehousing- TypeA suitablepieceof tubing,releasebothendsof , :Personalinjurymayresultifpadis , ,replaceif :If lowergearleveris tobereplacedthenballpinseating, ,replaceif ,replaceif purposegreaseandfit ,positionlowergearleverin :Ensurenylonpadis ,tightenboltto housing,fit suitablepieceof tubinglocatebothendsof TypeA selectorshaft, trunnion, , :Retainshim(s).

10 , ,removeanddiscard O , O O ringto quadrant,fit :Ensurethatheadofpinis threadsof setscrew, threadsof blankingplug,fit trunnion,securewitha threadsof setscrew, ,fit TypeB :Toavoidpersonalinjury,restraineachsprin ginturnwitha newRailkobushandfit to gearchangehousingensuringballcrosspinsar elocatedin gearchangehousing, threadsof 2 securefrontof biasadjustmentplateandtightento pillarensuringlongestendof springis threadsof 2 suitablepairofgrips,ensureshortendof biasspringispositionedonoutsideedgeof :Personalinjurymayresultifbiasspringis biasspringis retainedbeneathwasher.