R380 GEARBOX. Manual — part 7
MANUAL GEARBOX
OVERHAUL
7
4. Place a suitable container underneath the box
to catch any oil spillage and remove the
extension housing.
5. Remove oil filter.
6. Secure centre plate to gear casing with 2 bolts
8 x 35mm.
Extension housing - Type C gearbox - Remove
1. Remove and discard self-locking nut securing
selector shaft pin to selector shaft; remove pin.
2. Carefully prise speedometer pinion housing
and gear out of extension housing, remove and
discard ’O’ ring.
3. Remove 5th gear spool retainer, remove and
discard ’O’ ring.
4. Noting their fitted position, remove 10 bolts
securing extension housing to gearcase.
5. Using a soft faced mallet, tap extension
housing to free it from locating dowels.
6. Remove extension housing.
NOTE: Speedometer drive gear may be a
tight fit on output shaft and this can
prevent removal of extension housing.
Insert suitable blocks of wood between
extension housing and centre plate and carefully
lever extension housing away until drive gear is
released.
7. Remove and discard selector shaft oil seal.
8. Secure centre plate to gearcase with 2 bolts 8
x 35mm.
MANUAL GEARBOX
8
OVERHAUL
Extension housing - Type D gearbox - Remove
1. Remove reverse gear/5th gear selector spool
retainer.
2. Remove 10 bolts securing extension case to
main gearcase, noting position of longer bolts.
3. Place a suitable container underneath the box
to catch any oil spillage.
4. Using a soft faced mallet, tap extension
housing free from its location dowels.
5. Remove extension housing.
6. Remove oil filter.
5th and Reverse gear - Remove
MANUAL GEARBOX
OVERHAUL
9
1. Using a suitable two legged puller remove 5th
gear layshaft support bearing track from the
end of layshaft.
2. Using tool LRT-37-023 to hold the 5th laygear,
remove the 5th laygear nut.
3. Remove thrust collar segments, retaining ring
and segments, drift out the roll pin.
4.
Later gearboxes: Remove split washer
securing 5th laygear to shaft.
5. Remove 5th laygear.
6. Remove mainshaft rear support bearing track
using tools LRT-37-009 and LRT-37-024.
7. Remove 12mm bolt from end of mainshaft.
8. Remove mainshaft 5th gear with synchromesh
baulk ring.
9. Remove mainshaft 5th gear split needle roller
bearing.
10. Remove circlip securing 5th gear synchromesh
hub.
11. Rotate selector spool clear of synchro hub fork
and remove 5th and reverse synchromesh hub
assembly complete with fork and spool.
12. Remove mainshaft reverse gear complete with
needle roller bearing and bush noting
selectable spacer between reverse gear bush
and centre plate bearing.
13. Remove layshaft reverse gear.
14. Remove centre plate detent plug, spring and
ball.
15. Remove 2 bolts securing spool retainer,
remove retainer.
16. Remove ’slave’ bolts.
MANUAL GEARBOX
10
OVERHAUL
Mainshaft and layshaft - Remove
1. Align selector shaft pin with slot in centre plate
and using wooden blocks and hide mallet,
drive off centre plate.
2. Collect detent ball and spring, remove bearing
tracks and shims.
3. Remove layshaft, mainshaft and selector shaft
from casing as complete unit.
4. Remove input shaft, and 4th gear baulk ring. (If
not already removed with mainshaft).
Mainshaft - Dismantle
1. Using LRT-99-002 and support bars under 1st
gear, press mainshaft support bearing from
mainshaft.
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