Discovery 2. Manual — part 545

MANUAL GEARBOX - R380

OVERHAUL

37-33

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

remove pilot bearing track from input shaft.

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.

MANUAL GEARBOX - R380

37-34

OVERHAUL

Reassembly

1. Clean input shaft and bearing/oil seal recess in

front cover.

2. Lubricate a new input shaft oil seal with

gearbox oil.

3. Fit oil seal using a suitable mandrel.
4. Using a press and a suitable mandrel, fit

bearing outer track in front cover.

5. Using a press and a suitable mandrel, fit pilot

bearing outer track to input shaft.

6. Using tool LRT-37-043, LRT-37–043/2 and

LRT-99-002, fit new taper bearing to input
shaft.

7. Using tool LRT-99-002 and a suitable mandrel,

press new pilot bearing onto output shaft.

8. Position input shaft to gearbox case.
9. With assistance, fit output shaft and layshaft

assembly into gearbox case.

10. Fit reverse idler gear shaft.

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MANUAL GEARBOX - R380,

OVERHAUL, Shaft - reverse idler.

11. Fit gearbox front cover.

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MANUAL GEARBOX - R380,

OVERHAUL, Cover - front.

MANUAL GEARBOX - R380

OVERHAUL

37-35

Extension - gearbox rear

$% 37.12.01

Disassembly

1. Remove 4 bolts and remove gear selector

housing.

2. Using tools LRT-37-009, LRT-37-001/2 and

LRT-37-010 , remove output shaft oil seal
collar.

3. Remove bolt securing interlock spool retainer

and discard 'O' ring.

4. Noting fitted position of 2 longest bolts, remove

10 bolts securing extension housing to
gearbox.

5. Remove extension housing from gearbox

centre plate.

MANUAL GEARBOX - R380

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OVERHAUL

6. Fit 2 off 8x35 mm slave bolts to secure centre

plate to gearbox casing.

7. Remove 3 Torx screws, remove oil pump and

discard 'O' ring.

8. Drift out layshaft support bearing.
9. Remove and discard output shaft rear oil seal.

10. Remove oil pick-up pipe.
11. Drift out output shaft support bearing and oil

pick-up ring.

12. Remove reverse inhibitor shaft, cam and

spring.

13. Remove 2 bolts and remove gate plate.

14. Remove reverse light switch and discard

sealing washer.

15. Remove 2 bolts, remove oil cooler by-pass and

discard 'O' rings.

Reassembly

1. Clean extension housing and mating faces.
2. Clean oil cooler by-pass.
3. Using new 'O' rings, fit oil cooler by-pass and

tighten bolts to 15 Nm (11 lbf.ft).

4. Using new sealing washer, fit reverse light

switch and tighten to 24 Nm (17 lbf.ft).

5. Fit reverse inhibitor spring and cam.
6. Clean threads of reverse inhibitor shaft and

gate plate bolts.

7. Apply Loctite 290 to threads of reverse inhibitor

shaft, fit and tighten shaft.

8. Apply Loctite 290 to threads of gate plate bolts.
9. Position gate plate and tighten bolts to 15 Nm

(11 lbf.ft).

10. Fit output shaft support bearing and oil pick-up

ring. Align tag with centre of drain slot.

11. Fit layshaft support bearing.

12. Fit new output shaft oil seal using tool LRT-37-

014.