Discovery 2. Manual — part 544
MANUAL GEARBOX - R380
OVERHAUL
37-29
20. 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)
21. Check output shaft and layshaft end float as
follows.
22. The end float setting for both shafts is:
l
New = 0.00 to 0.05 mm (0.0 to - 0.002 in)
l
Service limit = 0.05 mm (0.002 in)
23. Fit front cover to gearbox case without the oil
seal and tighten bolts by diagonal selection to
25 Nm (18 lbf.ft).
24. Position in vice with front cover facing
downwards.
25. Fit input shaft to gearbox case less 4th gear
baulk ring.
26. Fit output shaft assembly to input shaft.
27. Fit output shaft bearing track and shim to centre
plate.
28. Fit centre plate to gearbox case and secure
using 8 slave bolts.
29. Rotate output shaft to settle bearings.
30. Fit a suitably large ball bearing into end of
output shaft.
31. Position a suitable DTI and zero probe on ball
bearing.
32. Lift output shaft and note DTI reading.
33. If reading is incorrect, dismantle and fit shim to
give correct end float.
34. Repeat above procedure.
35. Repeat procedure for layshaft end float.
36. Remove and discard 6 bolts and remove
gearbox front cover.
37. Fit gearbox selector fork - set.
OVERHAUL, Fork - set - selector shaft.
38. Fit gearbox front cover.
Synchroniser - gearbox - set
$% 37.20.07
Disassembly
1. Remove gearbox selector fork set.
OVERHAUL, Fork - set - selector shaft.
2. Using tool LRT-99-002 and support bars
under 1st gear, press output shaft bearing from
output shaft.
3. Remove 1st gear, bearing collar, needle roller
bearing and synchromesh rings.
4. Noting its fitted position, remove 1st / 2nd gear
synchroniser hub, 2nd gear synchromesh
rings, 2nd gear and needle roller bearing.
MANUAL GEARBOX - R380
37-30
OVERHAUL
5. Using tool LRT-99-002 and support bars under
3rd gear, press off output shaft pilot bearing.
6. Remove spacer, 3rd / 4th gear synchroniser
hub, synchromesh baulk rings, 3rd gear and
needle roller bearing.
7. Remove output shaft.
Reassembly
1. Clean output shaft, synchroniser hubs, gears
and bearings.
2. Position output shaft in protected vice jaws,
output end upwards.
3. Fit 2nd gear bearing, 2nd gear and
synchromesh baulk rings onto output shaft.
4. Position 1st / 2nd synchroniser hub onto output
shaft. Ensure that baulk rings are correctly
located in hub.
5. Position 1st gear synchromesh baulk rings,
needle roller bearing, 1st gear and bearing
collar onto output shaft. Ensure baulk rings are
correctly located in hub.
6. Remove output shaft from vice.
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)
MANUAL GEARBOX - R380
OVERHAUL
37-31
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.
OVERHAUL, Fork - set - selector shaft.
Fork - set - selector shaft
$% 37.16.45
Disassembly
1. Remove reverse idler gear shaft.
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).
MANUAL GEARBOX - R380
37-32
OVERHAUL
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.
OVERHAUL, Shaft - reverse idler.
Shaft - gearbox - input
$% 37.20.16
Disassembly
1. Remove gearbox front cover.
2. Remove reverse idler gear shaft.
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.
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