R380 GEARBOX. Manual — part 11
MANUAL GEARBOX
OVERHAUL
23
3. Using LRT-37-001 and LRT-99-002 remove
taper roller bearing.
4. Support the shaft under LRT-99-002 and press
in a new pilot bearing track.
5. Using LRT-99-002, Collets LRT-37-001 and
adapter LRT-37-002 fit a new taper bearing.
Mainshaft - Inspection
1. Examine bearing journals for wear and scores.
2. Examine splines for wear and damage.
3. Use an air line to check that the main oil feed
from pump and feed to spigot bearing are
clear.
4. Check oil feed holes to roller bearing are clear.
MANUAL GEARBOX
24
OVERHAUL
Layshaft - Overhaul
1. Using extractor tool LRT-99-002 and collets
LRT-37-022 withdraw layshaft bearings.
2. Examine layshaft for wear and damage.
NOTE: Layshaft and layshaft 5th gear
fitted to later gearboxes are machined to
enable fitment of a split washer to prevent
gear movement on shaft. The modified layshaft,
gear and split washer may be fitted to early
gearboxes as an assembly.
3. Using press LRT-99-002, and support bars fit
new taper roller bearings.
MANUAL GEARBOX
OVERHAUL
25
Mainshaft - Reassembly
1. Clamp mainshaft in protected vice jaws, output
end upwards.
2. Fit 2nd gear needle roller bearing, 2nd gear
and synchromesh baulk rings onto mainshaft.
(Rotate each baulk ring to ensure they locate
onto each other).
3. Assemble the 1st and 2nd synchromesh
selector hub onto mainshaft spline,
(note 2nd
speed side marking). Ensure that baulk ring
has located correctly inside hub.
(Rotate the
ring slightly as the hub is lowered).
4. Fit 1st gear synchromesh baulk rings, needle
roller bearing, 1st gear and bush onto
mainshaft ensuring baulk rings locate correctly
inside selector hub.
5. Using LRT-99-002, bearing guide LRT-37-019,
collets LRT-37-001 and adaptor LRT-37-002
press on mainshaft taper roller bearing taking
care not to disturb the lay of the synchromesh
baulk rings and gears.
6. Check the end float of the 1st and 2nd gear
assembly using a feeler gauge between the
gear and mainshaft bearing.
Maximum clearance:
1st gear: 0.05 - 0.20mm (0.002 - 0.008 in)
2nd gear: 0.04 - 0.21mm (0.0016 - 0.0083 in)
7. Invert mainshaft in vice and fit 3rd gear needle
roller bearing, third gear and synchromesh
baulk rings.
8. Assemble 3rd/4th gear synchromesh selector
hub (note 3rd speed side markings) onto
mainshaft splines taking care to locate the
baulk rings into recesses in the selector hub.
9. Fit spacer.
MANUAL GEARBOX
26
OVERHAUL
10. Using LRT-99-002 press on new pilot bearing.
Check end float of 3rd gear assembly as in
step 6.
Maximum clearance:
0.11 - 0.21mm .
Reverse idle gear - Reassembly
1. Examine components for wear and damage.
2. Assemble reverse idle gear needle roller
bearing, idle gear, spacer and shaft and using
suitable tool, press into centre plate.
Maximum clearance:
0.04 - 0.38mm (0.0016in - 0.015in)
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