Discovery 2. Manual — part 122

MANUAL GEARBOX - R380

OVERHAUL

37-45

6. Remove split collar and 5th gear from layshaft.

Reassembly

1. Clean gear and layshaft.
2. Position 5th gear and split collar to layshaft

ensuring that bevelled side of collar is towards
5th gear.

3. Position split collars and retaining ring securing

5th gear to output shaft.

4. Position tool LRT-37-023 to hold 5th gear and

tighten new stake nut to 220 Nm (162 lbf.ft) and
stake nut.

5. Apply a small amount of heat and fit support

bearing track to layshaft.

6. Fit gearbox extension.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380

37-46

OVERHAUL

Bearing - layshaft rear support

$% 37.20.58

Disassembly

1. Remove extension housing.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

2. Remove 3 Torx screws, remove oil pump and

discard 'O' ring.

3. Drift out layshaft support bearing.

4. Using a suitable two legged puller remove 5th

gear layshaft support bearing track from end of
layshaft.

Reassembly

1. Clean layshaft and bearing recess in extension

housing.

2. Fit layshaft support bearing.
3. Clean oil pump recess in extension housing,

ensure screw holes are clean and dry.

4. Lubricate oil pump recess in housing with

gearbox oil.

5. Lubricate a new 'O' ring with gearbox oil and fit

to oil pump.

6. Locate oil pump in extension housing with word

'TOP' towards top of housing.

7. Align fixing screw holes and tap pump lightly

around edges until pump is fully in housing. Do
not pull pump into housing by tightening
screws.

8. Fit Torx screws and tighten to 6 Nm (4.5 lbf.ft).
9. Apply a small amount of heat and fit support

bearing track to layshaft.

10. Fit extension housing.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

MANUAL GEARBOX - R380

OVERHAUL

37-47

Bearing - output shaft rear support

$% 37.20.55

Disassembly

1. Remove extension housing.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

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

LRT-37-010, remove output shaft support
bearing track.

3. Remove output shaft rear oil seal.

4. Remove output shaft support bearing and oil

pick-up ring.

Reassembly

1. Clean output shaft and bearing recess in

extension housing.

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

ring. (Align tag with centre of drain slot).

3. Fit new output shaft oil seal using LRT-37-014.

MANUAL GEARBOX - R380

37-48

OVERHAUL

4. Using tool LRT-37-015 and LRT-37-021, fit

support bearing track to output shaft.

5. Fit extension housing.

+

MANUAL GEARBOX - R380,

OVERHAUL, Extension - gearbox rear.

Shaft - reverse idler

$% 37.20.13

Disassembly

1. Remove 5th / reverse gear synchroniser.

+

MANUAL GEARBOX - R380,

OVERHAUL, Synchronizer assembly - 5th/
reverse.

2. Remove reverse gear complete with needle

roller bearing and collar noting selective spacer
between collar and centre plate bearing.

3. Remove layshaft reverse gear noting oil groove

faces centre plate bearing.

4. Remove detent screw from centre plate and

collect upper detent ball and spring.