Discovery 2. Manual — part 548

MANUAL GEARBOX - R380

OVERHAUL

37-45

5. Remove 2 bolts securing spool retainer to

gearbox case. Remove retainer, remove and
discard 'O' ring - if fitted.

6. Remove interlock spool from selector shaft.

7. Remove filter from gearbox case.

8. Align selector shaft pin with slot in centre plate

and using wooden blocks and hide mallet,
release centre plate and collect lower detent
ball and spring.

9. Press out reverse idler shaft using a suitable

press.

10. Remove idler gear, needle roller bearing and

spacer.

Reassembly

1. Clean centre plate and reverse gear

components.

2. Lubricate gearbox components with clean gear

oil.

3. Position idler gear, bearing and spacer to idler

shaft.

4. Using a suitable press fit idler shaft to centre

plate.

5. Using feeler gauges, check clearance between

reverse idler and shaft flange; fit a thicker or
thinner spacer if necessary in order to achieve
correct clearance:

l

New clearance = 0.04 - 0.38 mm (0.002 -
0.015 in)

l

Service limit = 0.38 mm (0.015 in)

6. Apply sealant, Part No. STC 3254 to gearbox

casing.

7. Fit lower spring and detent ball into centre

plate, retain using a dummy shaft.

8. Align selector shaft pin with slot in centre plate.
9. Fit centre plate and fit 2 off 8x35 mm slave bolts

to retain centre plate in position on gearbox
case; recover dummy shaft.

MANUAL GEARBOX - R380

37-46

OVERHAUL

10. Fit filter to gearbox case.
11. Fit interlock spool to selector shaft.
12. Using new 'O' ring, fit spool retainer and tighten

bolts to 8 Nm (6 lbf.ft).

13. Clean threads of detent plug.
14. Apply Loctite 290 to threads of detent plug, fit

upper detent ball and spring.

15. Fit detent plug and tighten to 25 Nm (18 lbf.ft).
16. Position reverse gear to layshaft.
17. Position reverse gear complete with bearing,

collar and selective spacer to output shaft.

18. Fit 5th / reverse gear synchroniser.

+

MANUAL GEARBOX - R380,

OVERHAUL, Synchronizer assembly - 5th/
reverse.

Housing - gear selector mechanism

$% 37.16.37.01

Disassembly

1. Remove 4 bolts and remove gear selector

housing.

Reassembly

1. Clean mating faces on selector housing and

gearbox.

2. Apply sealant, STC 3254, to selector housing.
3. Clean selector housing bolt threads.
4. Apply Loctite 290 to threads of selector housing

bolts, position selector housing and tighten
bolts to 25 Nm (18 lbf.ft)

5. Adjust gear lever bias springs.

+

MANUAL GEARBOX - R380,

ADJUSTMENTS, Spring - gear lever bias.

MANUAL GEARBOX - R380

OVERHAUL

37-47

Lever - gear change

$% 37.16.04

Disassembly

1. Remove gear selector housing.

+

MANUAL GEARBOX - R380,

OVERHAUL, Housing - gear selector
mechanism.

2. Restrain right hand bias spring using a suitable

pair of grips.

3. Remove 2 bolts securing right hand side of bias

spring adjustment plate.

4. Repeat operations for left hand bias spring.
5. Remove bias springs and adjustment plate.

6. Remove lower gear lever.
7. Remove and discard Railko bush.
8. Remove and discard oil seal from housing.

Reassembly

1. Clean components.
2. Apply multi-purpose grease to ball and cross

pins.

3. Apply multi-purpose to new Railko bush and fit

to housing ensuring that slots are correctly
aligned.

4. Lubricate a new seal with gearbox oil and fit, lip

side towards housing using a suitable mandrel.

5. Position lower gear lever to selector housing

ensuring cross pins are located in Railko bush.

6. Position bias spring adjustment plate to

selector housing.

7. Clean threads of bias spring adjustment plate

bolts and apply Loctite 290 to threads.

8. Fit 2 short bolts to secure front of adjustment

plate and tighten to 25 Nm (18 lbf.ft).

9. Position right hand bias spring to pillar ensuring

longest end of spring is against gear lever.

10. Restrain bias spring using a suitable pair of

grips, ensure shortest end of spring is on
outside edge of bolt hole.

MANUAL GEARBOX - R380

37-48

OVERHAUL

11. Fit longest bolt and washer ensuring end of

bias spring is under washer, tighten bolt to 25
Nm (18 lbf.ft).

12. Repeat above procedures for remaining bias

spring.

13. Fit gear selector housing.

+

MANUAL GEARBOX - R380,

OVERHAUL, Housing - gear selector
mechanism.

14. Adjust gear lever bias springs.

+

MANUAL GEARBOX - R380,

ADJUSTMENTS, Spring - gear lever bias.

Housing - clutch

$% 37.12.07

Disassembly

1. Remove clutch release bearing and operating

lever.

2. Remove 6 bolts and remove clutch housing.

Reassembly

1. Clean clutch housing and gearbox mating face.
2. Position clutch housing and tighten bolts to 75

Nm (55 lbf.ft).

3. Fit clutch operating lever and release bearing.