Discovery 2. Manual — part 118

MANUAL GEARBOX - R380

OVERHAUL

37-29

13. Using tool LRT-37-022 and LRT-99-002,

remove bearing from 4th gear end of layshaft.

Reassembly

1. Clean layshaft, input shaft and output shaft

bearing surfaces.

2. Using tool LRT-37-022, LRT-37-044 and

LRT-99-002, press new bearing onto splined
end of layshaft.

3. Using tool LRT-37-022 and LRT-99-002,

press new bearing onto 4th gear end of
layshaft.

MANUAL GEARBOX - R380

37-30

OVERHAUL

4. Using tools LRT-37-043, LRT-37-043/2 and

LRT-99-002, press new bearing onto input
shaft.

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

fit input shaft outer bearing track to front cover.

6. Fit layshaft bearing track to front cover.
7. Using tool LRT-99-002 and a suitable mandrel,

fit pilot bearing outer track to input shaft.

8. Clean synchroniser hubs, gears and bearings.
9. Position output shaft in protected vice jaws,

output end upwards.

10. Fit 2nd gear bearing, 2nd gear and

synchromesh baulk rings onto output shaft.

11. Position 1st / 2nd synchroniser hub onto output

shaft. Ensure that baulk rings are correctly
located in hub.

12. 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.

13. Remove output shaft from vice.

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

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

15. Using a feeler gauge, check end float of 1st

gear 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)

16. Using a feeler gauge, check end float of 2nd

gear 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

17. Invert output shaft in vise and fit 3rd gear,

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

18. Remove output shaft from vice.

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

press pilot bearing onto output shaft.

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.

+

MANUAL GEARBOX - R380,

OVERHAUL, Fork - set - selector shaft.

38. Fit gearbox front cover.

+

MANUAL GEARBOX - R380,

OVERHAUL, Cover - front.

MANUAL GEARBOX - R380

37-32

OVERHAUL

Synchroniser - gearbox - set

$% 37.20.07

Disassembly

1. Remove gearbox selector fork set.

+

MANUAL GEARBOX - R380,

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.

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.