R380 GEARBOX. Manual — part 1
INTRODUCTION
INTRODUCTION
1
INTRODUCTION
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 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 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.
WARNINGS, CAUTIONS and Notes have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
References
Operations covered in this manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary, a road test of the
vehicle is carried out, particularly where safety
related items are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service Limits where applicable.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Rover/Land Rover recommended parts are
used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features embodied in the car may be
impaired if other than Rover/Land Rover
recommended parts are fitted. In certain territories,
legislation prohibits the fitting of parts not to the
manufacturer’s specification.
Torque wrench setting figures given in this Manual
must be used. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is
impaired during removal it must be renewed.
The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Rover/Land
Rover recommended parts. All Rover/Land Rover
recommended parts have the full backing of the
vehicle Warranty.
Rover/Land Rover Dealers are obliged to supply
only recommended parts.
INTRODUCTION
2
INTRODUCTION
SPECIFICATION
Rover/Land Rover are constantly seeking to improve
the specification, design and production of their
vehicles and alterations take place accordingly.
While every effort has been made to ensure the
accuracy of this Manual, it should not be regarded
as an infallible guide to current specifications of any
particular component or vehicle.
This Manual does not constitute an offer for sale of
any particular component or vehicle. Rover/Land
Rover Dealers are not agents of Rover/Land Rover
and have no authority to bind the manufacturer by
any expressed or implied undertaking or
representation.
GEARBOX IDENTIFICATION
The procedures given in this manual cover overhaul
of the R380 gearbox fitted to a range of vehicles and
as such, certain differences exist between
gearboxes, particularly in respect of the extension
housings, gear change housings and transfer box
selector housings. It is important therefore that
before starting work, the gearbox to be overhauled is
correctly identified. Identification can be made by
noting the gearbox serial number prefix stamped on
the RH side of the gearbox casing and referring to
the following table which lists four types of gearbox,
A, B, C and D together with their appropriate serial
number prefixes.
NOTE: The gearbox types listed are only
intended as an aid to identification and do
not relate to gearbox part numbers or a
particular vehicle.
Overhaul operations in this manual list the
applicable gearbox type referred to and it is
important that the relevant operation is followed.
Type A gearbox prefixes: - 50A; 51A; 56A; 58A;
60A; 61A;
Type B gearbox prefixes: - 53A; 55A; 63A
Type C gearbox prefix: - 18A
Type D gearbox prefixes: - 64A; 65A
MANUAL GEARBOX
GENERAL DATA
1
REVISED: 12/96
GENERAL DATA
NEW
SERVICE LIMIT
Baulk ring clearances
0.5 mm (0.02 in)
1st gear end float
0.05 - 0.20 mm
(0.002 - 0.008 in)
0.327 mm (0.013 in)
2nd gear end float
0.04 - 0.21 mm
(0.0016 - 0.0083 in)
0.337 mm (0.13 in)
3rd gear end float
0.11 - 0.21 mm
(0.004 - 0.0083 in)
0.337 mm (0.13 in)
Adjust 5th - reverse hub - shim to -
0.005 - 0.055 mm
(0.002 - 0.022 in)
0.055 mm (0.022 in)
Reverse gear idler shaft clearance
0.04 - 0.38 mm
(0.0016 - 0.015 in)
0.38 mm (0.015 in)
Mainshaft end float
0.01 - 0.06 mm
(0.0004 - 0.0024in)
0.06 mm (0.0024 in)
Layshaft end float
0.01 - 0.06 mm
(0.0004 to 0.0024 in) 0.06 mm (0.0024 in)
Lubricants
ATF M2C33 F or G
Capacities
Oil cooler fitted = 3.4 litres
Non oil cooler type = 2.9 litres
Sealants
Joint faces - Hylosil RTV 102
Available through Unipart
Bolts and filler plug - Loctite 270 or Marston Bentley
Hylogrip 640 (studlock)
MANUAL GEARBOX
TORQUE WRENCH SETTINGS
1
REVISED: 12/96
TORQUE WRENCH SETTINGS
Oil pump to extension case
6 Nm
Attachment plate to gearcase
8 Nm
Attachment plate to remote housing
8 Nm
Bottom cover to clutch housing
8 Nm
Breather baffle
8 Nm
Clip to clutch release lever
8 Nm
Cover to gear change housing
8 Nm
Spool retainer to gear case
8 Nm
Torsion spring locknut - adjusting screw
8 Nm
Screw - gear lever retention
8 Nm
Breather
15 Nm
Gear lever retainer bolt
15 Nm
Reverse inhibitor shaft
16 Nm
Reverse light switch
24 Nm
Transfer box to remote housing bolts
25 Nm
Bias adjustment plate bolts
25 Nm
Selector quadrant setscrew
25 Nm
Gear change lever yoke setscrew
25 Nm
Adjustment plate to gear change housing
25 Nm
Extension case to gear case
25 Nm
Front cover to gear case
25 Nm
Gear change housing to extension case
25 Nm
Gear lever housing to remote housing
25 Nm
Guide - clutch release sleeve to bell housing
25 Nm
Mounting bracket
25 Nm
Pivot clutch lever to bell housing
25 Nm
Pivot plate to bell housing
25 Nm
Plug - detent ball and spring
25 Nm
Plunger housing to gear change housing
25 Nm
Remote selector housing to extension case
25 Nm
Slave cylinder to clutch housing
25 Nm
Upper gear lever assembly to lower gear lever 25 Nm
Yoke to selector shaft
25 Nm
Filler plug
30 Nm
Oil level plug
30 Nm
Oil drain plug
50 Nm
Clutch housing to gearbox
72 Nm
Output flange bolt
90 Nm
5th gear layshaft stake nut
220 Nm
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