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: 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 .

2 Thegearboxto thegearboxcasingandreferringtothefollowi ngtablewhichlistsfourtypesof gearbox ,A,B,C andD thismanuallisttheapplicablegearboxtypere ferredto andit isimportantthattherelevantoperationis gearboxprefixes:- 50A;51A;56A;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 NmAdjustmentplateto gearchangehousing25 NmExtensioncaseto gearcase25 NmFrontcoverto gearcase25 NmGearchangehousingto extensioncase25 NmGearleverhousingto remotehousing25 NmGuide- clutchreleasesleeveto bellhousing25 NmMountingbracket25 NmPivotclutchleverto bellhousing25 NmPivotplateto bellhousing25 NmPlug- detentballandspring25

3 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, :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.

4 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: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.

5 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).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).

6 , 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). , ,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.

7 Tightenboltto TypeC boltsand2 , boltsandwasherssecuringbottomcoverplate, , , , TypeD gearboxNOTE:TheremotegearchangefittedtoT ypeD gearboxesis it is :Bushesmaybepressedinandoutofremotehousi ngusinga , rattlespringfordistortionandplungerforwe ar;replaceif ,crosspinsandbushselectorrodyokeballsfor wear, yokeballsareworn,removeanddiscardcirclip , purposegreaseandpressintoyoke; , mountingrubbers,replaceasa setif ,insertrodin selectorrod,fit locatedinyokeandanti- ,fit , TypeA , ,removeanddiscard2 , countersunkheadscrewssecuringendcoverto ,removeanddiscard2 O ,removeanddiscard2 O ,replaceif O ringswithgearboxoilandfit toselectorfork,positionforkin purposegreaseandlocatelongestendof shaftin O ringswithgearboxoilandfit ,fit gearleverensuringthatgroovein seatingis crossshaft;retainwitha gearlever,locateinselectorforkandfit , :Example A showsa B showstheroundedcornersofa :Hubsandsleeveshavea Notch1st2 gearside-2nd3rd/4th-3 Notches3rd--4th5th/Rev-5 springeachsideof thesynchromeshassemblyensuringthestepone achspringlocatesona ( ).

8 Inputshaft- a , ColletsLRT-37-001andadapterLRT-37-002fit a checkthatthemainoilfeedfrompumpandfeedto :Layshaftandlayshaft5thgearfittedtolater gearboxesaremachinedtoenablefitmentofa , , protectedvicejaws, ,2ndgearandsynchromeshbaulkringsontomain shaft.(Rotateeachbaulkringto ensuretheylocateontoeachother). ,(note2ndspeedsidemarking).Ensurethatbau lkringhaslocatedcorrectlyinsidehub.(Rota tetheringslightlyasthehubis lowered). ,needlerollerbearing, , bearingguideLRT-37-019,colletsLRT-37-001 andadaptorLRT-37-002pressonmainshafttape rrollerbearingtakingcarenotto disturbthelayof the1stand2ndgearassemblyusinga :1 ( )2 ( ) viceandfit 3rdgearneedlerollerbearing, (note3rdspeedsidemarkings)ontomainshafts plinestakingcareto locatethebaulkringsintorecessesin ,idlegear,spacerandshaftandusingsuitable tool, ( )MANUALGEARBOXOVERHAUL27 Selectors- :Theselectorrailandforkis onlysuppliedasa TypeA TypeB andD gearboxesSelectoryoke- TypeC jawof jawof spoollocatesoverpinkeepingthespoolengage din 3 achievedbyclampingthemainshaftandlayshaf tseparatelybetweenthecentreplateandmainc asingandmeasuringthemovementoneachshaftw itha ( 0.)

9 0024in).Shimsto makeuptherequiredclearancesareplacedunde rthebearingtracksof slave rearof ,useadummybarto neutralandfit selectorshaftassemblyto fitteddownto :Earlytypeseal- waxcoated- or3 slave O ringandfit , , mainshaftsplinesandselectorshaft.(Ensure synchromeshbaulkringlocatesinsidehub). :Thefitofthecirclipis ( ). mainshaft,fit :Fitsplitwasherto holdlayshaft5thgear,tightenthelayshaft5t hgearnutto heatandfit engagein TypeA andB slave matingsurfacesandfit extensionhousingensuringoilpipelocatesin :Donotuseforce,if necessary,removeextensionhousingandre- extensioncasespoolretainer,fit retainerandtightenboltto 8 TypeC gearbox - uppipelocatesin filteranddrivelocatesin :Donotuseforce,if necessary,removeextensionhousingandre- roundnosedpunch, new O ringwithgearboxoilandfit pinionmeshwiththoseof 8 selectorshaft,fit andtightena newself- O TypeD gearbox - slave matingsurfacesandfit necessary, extensioncasespoolretainer,fit andtightenboltto 8 TypeA gearbox - threadof a TypeB gearbox - threadsof a newsetscrew,fit andtightenscrewto TypeD threadsof TypeA gearbox - matingsurfacesandfit to boltsin TypeA newgasketwithgreaseandfit TypeA gearbox - newgasketwithgreaseandfit remotehousingensuringgearleverballis ,transferboxselectorhousingandgearchange housingboltsto TypeB newgasketwithgreaseandfit.

10 Fit 4 boltsandtightento 25 NmMANUALGEARBOXOVERHAUL37 Gearchangehousing- TypeB gearbox - extensionhousingensuringthatgearleverpas sesthroughcentreof gearchangeleveryokeandengagesin TypeC gearbox - extensionhousingensuringselectorshaftpin is locatedin ,washersandmountingrubberssecuringremote gearchangeto extensionhousing;donottightenboltsat ,washersandmountingrubberssecuringbracke tto TypeD gearbox - gearlevertowardsleft,turnscrewclockwiseu ntilit feltat knob, TypeA gearboxNOTE:Thepurposeofthisadjustmentis tosetbothboltssothatthebiasspringlegsapp lyequalpressureonbothendsofthegearleverc rosspinwhenthirdorfourthgearis inneutral, lightloadto thegearleverin a TypeB gearchangehousing,applyHylogrip640to screwsandfit TypeC gearboxNOTE:Thepurposeofthisadjustmentis toensurethatwhenbiasspringiscorrectlyadj usted,thegearchangemechanismis automaticallyalignedfor3rdor4thgearselec tionwhengearleveris lightloadto movegearleverto theleftandright.