Discovery 2. Manual — part 119

MANUAL GEARBOX - R380

OVERHAUL

37-33

7. Using tool LRT-37-001, LRT-37-044 and

LRT-99-002, press taper bearing onto output
shaft.

8. Check end float of 1st gear using a feeler gauge

between gear and collar flange:

l

New = 0.05 - 0.20 mm (0.002 - 0.008 in)

l

Service limit = 0.327 mm (0.012 in)

9. Check end float of 2nd gear using a feeler

gauge between gear and output shaft flange:

l

New = 0.04 - 0.21 mm (0.0016 - 0.0083 in)

l

Service limit = 0.337 mm (0.013 in)

10. Invert output shaft in vice and fit 3rd gear,

bearing, baulk rings, 3rd / 4th synchroniser and
spacer.

11. Remove output shaft from vice.

12. Using tool LRT-99-002 and a suitable mandrel

press pilot bearing onto output shaft.

13. Check end float of 3rd gear between gear and

flange on output shaft.

l

New = 0.11 - 0.21 mm (0.004 - 0.0083 in)

l

Service limit = 0.337 mm (0.013 in)

14. Fit gearbox selector fork set.

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MANUAL GEARBOX - R380,

OVERHAUL, Fork - set - selector shaft.

MANUAL GEARBOX - R380

37-34

OVERHAUL

Fork - set - selector shaft

$% 37.16.45

Disassembly

1. Remove reverse idler gear shaft.

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MANUAL GEARBOX - R380,

OVERHAUL, Shaft - reverse idler.

2. With assistance, remove output shaft, selector

shaft and layshaft assemblies.

3. Remove selector shaft and fork assembly from

output shaft synchronisers.

4. Inspect the selector fork pads for wear, the

wear limit is 6.5 mm (2.559 in).

Reassembly

1. Clean selector shaft, forks and locations on

synchronisers.

2. Lubricate forks and shaft with clean gear oil.
3. Position selector shaft assembly to output shaft

synchronisers.

4. With assistance, fit output shaft and layshaft

assembly into gearbox case.

5. Fit reverse idler gear shaft.

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MANUAL GEARBOX - R380,

OVERHAUL, Shaft - reverse idler.

MANUAL GEARBOX - R380

OVERHAUL

37-35

Shaft - gearbox - input

$% 37.20.16

Disassembly

1. Remove gearbox front cover.

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MANUAL GEARBOX - R380,

OVERHAUL, Cover - front.

2. Remove reverse idler gear shaft.

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MANUAL GEARBOX - R380,

OVERHAUL, Shaft - reverse idler.

3. With assistance, remove output shaft, selector

shaft and layshaft as an assembly. Remove
selector shaft and fork.

4. Remove input shaft from gearbox case.

5. Using tool LRT-37-004, and LRT-99-004,

remove pilot bearing track from input shaft.

MANUAL GEARBOX - R380

37-36

OVERHAUL

6. Invert output shaft and using tool LRT- 99-002

and support bars under 3rd gear, press off pilot
bearing.

7. Using tool LRT-37-043 and LRT-99-002,

remove taper roller bearing from input shaft.

8. Using a suitable soft metal drift, remove

bearing outer track from front cover.

9. Remove and discard input shaft oil seal from

front cover.