r380 gearbox overhaul manual
Contents
1. Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool in use Operations also include reference to wear limits relevant data torque figures and specialist information and useful assembly details WARNINGS CAUTIONS and Notes have the following meanings WARNING Procedures which must be followed precisely to avoid the possibility of injury CAUTION Calls attention to procedures which must be followed to avoid damage to components NOTE Gives helpful information INTRODUCTION References Operations covered in this manual do not include reference to testing the vehicle after repair It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned Dimensions The dimensions quoted are to design engineering specification with Service Limits where applicable REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Rover Land Rover recommended parts are used Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories Safety features embodied in the car may be impaired if other than Rover Land Rover recommended parts are fitted In certain territories legislation prohibits the fitting of parts not to the manufacturer s specification T2. is retained beneath washer tighten bolt to 25 3 Remove 4 bolts and washers securing bottom Nm cover plate remove plate Repeat procedure for remaining bias spring 4 Remove bolt securing gear lever cap remove cap 5 Remove gear lever recover anti rattle spring and plunger 6 Remove pinch bolt securing selector rod yoke remove yoke 7 Withdraw selector rod from remote housing 8 Clean components OVERHAUL MANUAL GEARBOX 0 0 Remote gear change Type D gearbox Inspection 1 Check selector rod bushes in remote housing for wear NOTE Bushes may be pressed in and out of remote housing using a hand press and suitable mandrel 2 Check selector rod for wear replace if necessary 3 Check anti rattle spring for distortion and plunger for wear replace if necessary 4 Check gear lever ball pin cross pins and bush selector rod yoke balls for wear and replace if necessary If yoke balls are worn remove and discard circlip press ball and seating out of yoke 5 Lubricate replacement ball and seating with multi purpose grease and press into yoke secure using new circlip 6 Check bias spring for distortion replace if necessary 7 Check condition of mounting rubbers replace as a set if necessary Reassemble 37M7126 1 Lubricate selector rod and bushes with multi purpose grease insert rod in remote housing 2 Lubricate gear lever ball pin and selector rod NOTE The remote gear change
3. R380 Handgeschkelde R380 Boite de vitesses monvelle Manuel de r vision 380 Schaltgetriebe dria Vnd R380 Cambio meccanico Menvale di revisione R380 Cojo de cambios manual Manyal de revisi n R380 Caixa de velocidades manual Monual de revisao R380 GEARBOX OVERHAUL MANUAL This Overhaul Manual contains information applicable to the following models New Range Rover Range Rover Classic 1995 Models on Discovery 1995 Models on Defender 1995 Models on Publication Part No LRL 0003ENG 2nd Edition Published by Rover Technical Communication 1996 Rover Group Limited LAND lt ROVER INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevant sub section is given at the bottom of each page This manual contains procedures for overhaul of the R380 gearbox on the bench with the clutch and if applicable the transfer box removed For all other information regarding Adjustments Removal of oil seals clutch transfer box and gearbox unit consult the appropriate Repair Manual for the model concerned This manual is divided into 5 sections Data Torque Settings Service Tools Description and finally Overhaul To assist filing of revised information each sub section is numbered from page 1 The individual overhaul items are to be followed in the sequence in which they appear Items numbered in the illustrations are referred to in the text
4. the sleeve Examine all parts for damage and wear including spring clips for tension Check no excessive radial movement exist between inner members and mainshaft splines Examine inner and outer splines for wear OVERHAUL 21 MANUAL GEARBOX 37M7078 6 Examine the dog teeth on all gears for wear and damage NOTE Example A shows a tooth in good condition Example B shows the rounded corners of a worn tooth 7 Replace unit if excessively worn Reassembly 8 Refit inner hub to sleeve NOTE Hubs and sleeves have a master spline combination and can only be assembled one way The sleeves are further identified with a series of half moon notches which clearly identify which side of the assembly faces which gear Ensure the slot in the hub aligns with the centre notch on the sleeve Assy Sleeve Against Gear 1st 2nd 1 Notch 3rd 4th 3 Notches 5th Rev 5 Notches 9 Fit slippers and secure with a spring each side ofthe synchromesh assembly ensuring the step on each spring locates on a different slipper NOTE 5th and reverse synchromesh hubs have different springs noted by their yellow colour 22 OVERHAUL Checking baulk ring clearances Check clearance of all baulk rings and gears by pressing the baulk rings against the gear and measuring the gap The minimum clearance should be 0 5mm 0 020in 37M7079 Input shaft Overhaul 1 Examine the gear and dog teeth for wear a
5. Flange holder Hand press Impulse extractor SERVICE TOOLS 1 DESCRIPTION The R380 5 speed all synchromesh gearbox comprises an input shaft output shaft layshaft and reverse idler shaft Gearbox casings consist of a front cover gearcase centre plate and extension housing all casings are located by dowels and sealed Selector forks for 1st 2nd and 3rd 4th gears are located on a single selector shaft inside the main gearcase whilst the selector fork for fifth and reverse gear is located on the same selector shaft inside the extension housing MANUAL GEARBOX 0 0 The input shaft output shaft and layshaft are supported by taper roller bearings with all gears running on caged needle roller bearings Output shaft and layshaft bearings end float is controlled by selective thrust washers located in the centre plate Lubrication is by an oil pump located in the extension housing which directs oil via internal drillings in the output shaft to lubricate the components d Zong QD WU 37M7132 Mainshaft 1st gear Mainshaft 2nd gear Mainshaft 3rd gear Primary input shaft 4th gear Mainshaft 5th gear Layshaft Mainshaft Lubrication pump Oil filter 000 JO Om P AM ch REVISED 12 96 dE MI L IE IN IIN II 10 Breather 11 Single rail gear shift 12 1st 2nd synchromesh 13 Oil seals 14 3rd 4th gear synchromesh 15 5th revers
6. Noting their fitted position remove 3 bolts securing remote housing remove housing NOTE Dowel located 2 Remove 4 bolts securing transfer box selector ZN housing remove housing 3 Noting their fitted position remove 3 bolts Gear change selector housings Type B gearbox securing gear change housing remove Remove housing NOTE Dowel located A 37M7051 1 Remove 2 Torx screws securing gear change housing cover remove cover recover sealing rubber 4 OVERHAUL MANUAL GEARBOX 0 0 Selector quadrant Type A gearbox Remove Remote gear change Type C gearbox Remove ins 37M 053 1 Remove and discard set screw securing selector quadrant 2 Move selector shaft forwards remove quadrant 37M7055 Gear change lever yoke Type B gearbox Remove aa 1 Noting fitted positions of mounting rubbers and washers Rremove 2 bolts securing remote gear change to extension housing recover washers and mounting rubbers 2 Remove 2 bolts securing remote gear change bracket to extension housing recover washers and mounting rubbers 3 Release remote gear change from extension housing disconnect selector rod from selector shaft pin 37M7054 1 Remove and discard set screw securing yoke 2 Move selector shaft forwards remove yoke OVERHAUL 5 MANUAL GEARBOX Remote gear change Type D gearbox Remove 37M7121 1 Remove 4 bolts securing remote gear change to extension housing
7. 10 Withdraw cross shaft 11 Remove selector fork remove and discard 2 O rings 12 Clean all components Inspection 1 2 A 3 4 5 Check gaiter for splits and damage Check nylon seating and ball for wear replace if necessary CAUTION Seating and ball should be renewed as an assembly Check selector fork and clevis pin for wear Check cross shaft and end cover for wear Replace components as necessary Reassemble 1 2 Smear new O rings with gearbox oil and fit to selector fork position fork in housing Smear cross shaft with multi purpose grease and locate longest end of shaft in selector fork Smear new O rings with gearbox oil and fit to end cover Position end cover on cross shaft fit and tighten countersunk screws Assemble ball and nylon seating to gear lever ensuring that groove in seating is towards cross shaft Smear ball and nylon seating with multi purpose grease and locate in cross shaft retain with a new circlip Position new bushes to gear lever locate in selector fork and fit clevis pin Fit new spring clip to retain clevis pin Position gate plate and gaiter support plate to housing use new gaskets Fit retaining bolts and tighten to 15 Nm Fit gaiter MANUAL GEARBOX 0 0 Synchromesh assemblies Overhaul 1 37M7077 Remove spring clips from both sides of assembly Remove slippers and separate the hub from
8. 2 Release remote gear change from extension housing Gear change lever yoke Type D gearbox Remove 37M7122 1 Remove and discard set screw securing yoke 2 Move selector shaft forwards Remove yoke 6 OVERHAUL Extension housing Types A and B gearbox Remove 37M7056 1 Thread a 12mm bolt into the end of the output shaft and using tool LRT 37 009 and LRT 37 010 withdraw oil seal collar 37M7057 2 Remove reverse 5th gear selector spool retainer 3 Remove 10 bolts securing extension casing noting position of longer bolts MANUAL GEARBOX 0 0 Extension housing Type C gearbox Remove 37M7058 4 Place a suitable container underneath the box to catch any oil spillage and remove the extension housing 5 Remove oil filter 6 Secure centre plate to gear casing with 2 bolts 8 x 35mm 1 Remove and discard self locking nut securing selector shaft pin to selector shaft remove pin 2 Carefully prise speedometer pinion housing and gear out of extension housing remove and discard O ring 3 Remove 5th gear spool retainer remove and discard O ring 4 Noting their fitted position remove 10 bolts securing extension housing to gearcase 5 Using a soft faced mallet tap extension housing to free it from locating dowels 6 Remove extension housing NOTE Speedometer drive gear may be a tight fit on output shaft and this can prevent removal of extension housing Insert suitable
9. Invert mainshaft and using LRT 99 002 and support bars under 3rd gear press off pilot bearing OVERHAUL 11 MANUAL GEARBOX Gearbox casing Centre plate Dismantle Degrease and clean all components Inspect casing for damage cracks and stripped threads 1 Fit level plug 2 Fit new copper washer to drain plug Front Cover Dismantle 37M7069A 1 Remove bearing tracks and shims and check for wear and damage 2 Inspect for damage and selector rail bore for 37M7068 wear 1 Remove front cover and remove bearing 3 Remove splash shield if required tracks Check that spring clips are intact 4 Press out reverse idler gear shaft using 2 Remove oil seal from cover DO NOT fit new suitable press and check for wear seal at this stage 5 Remove idler gear needle bearing and spacer and check for wear and damage 6 Check centre plate detent balls for wear and springs for distortion replace as necessary 7 Check that threads of detent plug are not damaged NOTE Patchlok plug may be re used provided threads are undamaged 12 OVERHAUL Extension housing Types A and B gearbox Overhaul 1 Examine for damage to threads and machined faces 37M7070 oca 10 11 NOTE Types gearbox extension housing shown Remove three screws and remove oil pump Remove oil pick up pipe and check for obstruction Drift out layshaft support bearing Remove mainshaft re
10. N bush are aligned with slots in housing 10 11 12 13 18 Lubricate a new oil seal with gearbox oil Fit oil seal using a suitable mandrel Position gear lever to gear change housing Position bias spring adjustment plate to gear Apply Loctite 270 to threads of 2 short bias Fit bolts to secure front of bias adjustment Position bias spring to pillar ensuring longest Remote gear change Type C gearbox Check ball cross pin slots in gear change housing for wear Dismantle 2 Check ball and pins for wear 3 4 Replace worn components as necessary Check bias springs for distortion Apply multi purpose grease to ball and cross pins Apply multi purpose grease to new Railko bush and fit to gear change housing CAUTION Ensure that the slots in each ensuring ball cross pins are located in slots in housing and Railko bush change housing adjustment plate bolts plate and tighten to 25 Nm end of spring is against gear lever Apply Loctite 270 to threads of 2 long bias bias adjustment plate bolts Restrain bias spring using a suitable pair of grips ensure short end of bias spring is 37M7076 positioned on outside edge of bolt hole WARNING Personal injury may result if 1 Remove 2 bolts and 2 countersunk screws bias spring is not retained securing bias spring bridge plates 2 Remove bridge plates bridge plate liners and Fit bolt and washer ensuring end of bias spring bias spring
11. Tab washer Type C gearbox Drive flange bolt Type C gearbox Drive flange propeller shaft bolt Type C gearbox Support bracket Type C gearbox Support bracket bolt Type C gearbox Extension housing Type D gearbox Oil seal Type D gearbox DESCRIPTION AND OPERATION 5 MANUAL GEARBOX 37M7115 DESCRIPTION AND OPERATION 6 GEAR CHANGE HOUSING TYPE A GEARBOX Gear change housing Gasket Roll pin Bias spring Gear lever retaining bolt and washer Gear change housing bolts Gear lever Nylon pad and spring Gear lever extension Remote housing Blanking plug Selector shaft MANUAL GEARBOX 0 0 O ring Trunnion Circlip Trunnion retaining screw Selector quadrant Roll pin Shim Pin Ball pin seating 5th gear stop screw and locknut DESCRIPTION AND OPERATION 7 MANUAL GEARBOX 37M7116 DESCRIPTION AND OPERATION 8 GEAR CHANGE HOUSING TYPE B GEARBOX OD P OM ch Gear change housing cover and gasket Gear change housing Bias adjustment plate Lower gear lever Railko bush MANUAL GEARBOX 0 0 Lower gear lever housing oil seal Bias springs Bias spring retaining bolts Upper gear lever and bolt DESCRIPTION AND OPERATION 9 MANUAL GEARBOX 37M7117 DESCRIPTION AND OPERATION 10 REMOTE GEAR CHANGE HOUSING TYPE C GEARBOX oo xoo0n5romwza Remote gear change housing Sel
12. blocks of wood between extension housing and centre plate and carefully lever extension housing away until drive gear is released 7 Remove and discard selector shaft oil seal 8 Secure centre plate to gearcase with 2 bolts 8 x 3bmm OVERHAUL 7 MANUAL GEARBOX Extension housing Type D gearbox Remove 37M7123 2 Remove 10 bolts securing extension case to 37M7125 main gearcase noting position of longer bolts 3 Place a suitable container underneath the box to catch any oil spillage 4 Using a soft faced mallet tap extension housing free from its location dowels 5 Remove extension housing 6 Remove oil filter 1 Remove reverse gear 5th gear selector spool retainer 5th and Reverse gear Remove 37M7061A 8 OVERHAUL 10 11 12 13 Using a suitable two legged puller remove 5th gear layshaft support bearing track from the end of layshaft Remove thrust collar segments retaining ring 15 E Later gearboxes Remove split washer Remove 5th laygear P Na Remove mainshaft rear support bearing track Remove 12mm bolt from end of mainshaft Remove mainshaft 5th gear with synchromesh 37M7063A MANUAL GEARBOX 0 0 Using tool LRT 37 023 to hold the 5th laygear remove the 5th laygear nut and segments drift out the roll pin securing 5th laygear to shaft using tools LRT 37 009 and LRT 37 024 baulk ring Remove mainshaft 5th gear split needle ro
13. grease and fit to gearcase 2 Position transfer box selector housing to gearcase fit 4 bolts and tighten to 25 Nm MANUAL GEARBOX 0 0 Gear change housing Type B gearbox Refit Remote gear change Type D gearbox Refit 3 M7181 1 Apply Hylosil RTV 102 to mating surfaces of 37M7107 extension housing and remote gear change housing 2 Position remote gear change housing on 1 Apply Hylosil RTV 102 to mating surfaces of extension housing Ensure that gear lever ball extension housing is correctly located 2 Position gear change housing to extension 3 Fit bolts and tighten to 25 Nm housing ensuring that gear lever passes through centre of gear change lever yoke and engages in the gate plate 3 Fit bolts and tighten to 25 Nm 5th gear stop screw adjustment Type A gearbox 1 Select reverse gear While applying light Remote gear change Type C gearbox Refit pressure to gear lever towards left turn screw A AA EE POR clockwise until it contacts yoke 1 Apply lithium based grease to selector rod 2 Turn screw anti clockwise until 25 mm free yoke play is felt at knob ensure 5th gear can be 2 Position remote gear change to extension engaged housing ensuring selector shaft pin is located 3 Tighten locknut in selector rod yoke 4 Check all other gears are selectable 3 Fit bolts washers and mounting rubbers securing remote gear change to extension housing do not tighten bolts at this stage 4 Fit
14. on new pilot bearing Check end float of 3rd gear assembly as in step 6 Maximum clearance 0 11 0 21 26 OVERHAUL Reverse idle gear Reassembly 1 Examine components for wear and damage 37M7087 2 Assemble reverse idle gear needle roller bearing idle gear spacer and shaft and using suitable tool press into centre plate Maximum clearance 0 04 0 38mm 0 001 6in 0 015in MANUAL GEARBOX Selectors Inspection 1 Examine selector rail and pins for wear and LS damage N OS Selector yoke gearbox 37M7088 3 2 Examine selector forks for wear and damage NOTE The selector rail and fork is only A supplied as a complete assembly 37M7127 3 Examine interlock spools for wear and damage Selector quadrant Type A gearbox 4 Remove snap ring and examine selector yoke Examine selector quadrant and check for wear assembly 37M7089 Selector yoke Type B and D gearboxes OVERHAUL 27 MANUAL GEARBOX Assembling selectors 37M7091 1 Rest 1st 2nd fork and shaft assembly on bench and locate pin in jaw of fork 2 Fit interlock spool and 3rd 4th fork and engage spool in jaw of fork 37M7092 3 Slide spool and fork towards 1st 2nd selector until slot in spool locates over pin keeping the spool engaged in 3rd 4th fork jaw 28 OVERHAUL GEARBOX REASSEMBLE Mainshaft and layshaft end float NOTE The end float setting for both
15. wear 3 4 Replace worn components as necessary Check ball pin seating for wear Reassemble 1 Lubricate selector shaft and new O ring with gearbox oil 2 Fit O ring to selector shaft 3 Fit shaft to remote housing 4 Position rollers to quadrant fit pin and secure with new circlip CAUTION Ensure that head of pin is on opposite side of quadrant to selector shaft boss 5 Fit quadrant to selector shaft 6 Apply Loctite 270 to threads of setscrew fit and tighten setscrew 7 Apply Loctite 270 to threads of blanking plug fit and tighten plug 8 Smear ball pin seating with multi purpose grease 9 Position ball pin seating in trunnion secure with a new circlip 10 Position trunnion on selector shaft 11 Apply Loctite 270 to threads of setscrew fit and tighten setscrew 12 Fit 5th gear stop screw fit but do not tighten A locknut NOTE 5th gear stop screw adjustment is carried out during gearbox reassembly MANUAL GEARBOX 0 0 Gear change housing Type B gearbox 37M7075 Dismantle 37M7074 1 Remove bolts retaining bias springs WARNING To avoid personal injury restrain each spring in turn with a pair of grips while the bolts are being removed 2 Remove the two springs Remove remaining bolts to release lower lever assembly Remove and discard Railko bush Remove and discard oil seal OVERHAUL 17 MANUAL GEARBOX Inspection 1 Reassemble 1 2
16. 6 mm 0 0024 in 0 0004 to 0 0024 in 0 06 mm 0 0024 in ATF M2C33 F or G Oil cooler fitted 3 4 litres Non oil cooler type 2 9 litres Joint faces Hylosil RTV 102 Available through Unipart Bolts and filler plug Loctite 270 or Marston Bentley Hylogrip 640 studlock GENERAL DATA 1 MANUAL GEARBOX 0 0 TORQUE WRENCH SETTINGS Oil pump to extension case 6 Nm Attachment plate to gearcase 8 Nm Attachment plate to remote housing 8 Nm Bottom cover to clutch housing 8 Nm Breather baffle 8 Nm Clip to clutch release lever 8 Nm Cover to gear change housing 8 Nm Spool retainer to gear case 8 Nm Torsion spring locknut adjusting screw 8 Nm Screw gear lever retention 8 Nm Breather 15 Nm Gear lever retainer bolt 15 Nm Reverse inhibitor shaft 16 Nm Reverse light switch 24 Nm Transfer box to remote housing bolts 25 Nm Bias adjustment plate bolts 25 Nm Selector quadrant setscrew 25 Nm Gear change lever yoke setscrew 25 Nm Adjustment plate to gear change housing 25 Nm Extension case to gear case 25 Nm Front cover to gear case 25 Nm Gear change housing to extension case 25 Nm Gear lever housing to remote housing 25 Nm Guide clutch release sleeve to bell housing 25 Nm Mounting bracket 25 Nm Pivot clutch lever to bell housing 25 Nm Pivot plate to bell housing 25 Nm Plug detent ball and spring 25 Nm Plunger housing to gear change housing 25 Nm Remote selector housing to extension case 25 Nm Slave cylinder to clutch ho
17. D 4 AAA ec 37M7101 3 Apply Hylosil RTV 102 to mating surfaces and fit extension housing ensuring oil pipe locates in filter and roller bearings are not dislodged CAUTION Do not use force if necessary remove extension housing and re align oil pump drive 4 Bolt extension housing to centre plate and main casing MANUAL GEARBOX 0 0 Extension housing Type C gearbox Refit Lubricate a new selector shaft oil seal with gearbox oil Fit selector shaft oil seal Refit oil filter Apply Hylosil RTV 102 to mating surfaces Fit extension housing ensuring oil pick up pipe locates in filter and drive locates in oil pump oF CAUTION Do not use force if necessary remove extension housing and re align oil pump drive 37M7102 6 Fit extension housing bolts and tighten by diagonal selection to 25 Nm 7 Fit spacer 5 Apply Hylosil RTV 102 to extension case spool 8 Position speedometer drive gear on output retainer fit retainer and tighten bolt to 8 Nm shaft splines 9 Using a round nosed punch carefully tap speedometer drive gear into position 10 Smear a new O ring with gearbox oil and fit to speedometer pinion housing 11 Lubricate speedometer pinion with silicone grease 12 Fit speedometer pinion housing ensuring teeth of pinion mesh with those of driven gear 13 Apply Hylosil RTV 102 and fit 5th gear spool guide Tighten bolt to 8 Nm 14 Fit sel
18. ar oil seal Drift out mainshaft support bearing and oil pick up ring Remove shaft retaining reverse inhibition cam Remove reverse inhibition cam and spring Remove reverse light switch and sealing washer Remove gate plate Check all components for wear and renew as required MANUAL GEARBOX 0 0 Type C gearbox As for A and B Types and including the following 12 Recover speedometer dive gear and spacer 13 Check speedometer drive gear for wear and damage renew if necessary 14 Check speedometer pinion for wear and damage Check that scrolling on shaft is clear renew pinion and shaft if necessary 15 Check slots in 5th gear spool guide for wear renew spool guide if necessary Type C and D gearboxes CAUTION The rear mainshaft oil seal fitted to Type C and D extension housings is different to Types A and B When levering out seal take care not to damage the seal location surfaces 37M7124 NOTE Type D gearbox extension housing A shown 1 Lever out mainshaft oil seal taking care not to damage the location surfaces OVERHAUL 13 MANUAL GEARBOX Reassembly 1 2 Smear a light coat of petroleum jelly into the pump recess Renew O ring and press pump unit firmly into recess NOTE Ensure TOP marking on pump is A to top of casing 3 Tap pump lightly at edges until fully home NOTE Ensure good thread engagement before tightening 37M7071 10 Ap
19. before starting work the gearbox to be overhauled is correctly identified Identification can be made by noting the gearbox serial number prefix stamped on the RH side of the gearbox casing and referring to the following table which lists four types of gearbox A B C and D together with their appropriate serial number prefixes NOTE The gearbox types listed are only intended as an aid to identification and do not relate to gearbox part numbers or a particular vehicle Overhaul operations in this manual list the applicable gearbox type referred to and it is important that the relevant operation is followed Type A gearbox prefixes 50A 51A 56A 58A 60A 61A Type B gearbox prefixes 53A 55A 63A Type C gearbox prefix 18A Type D gearbox prefixes 64A 65A GENERAL DATA Baulk ring clearances 1st gear end float 2nd gear end float 3rd gear end float Adjust 5th reverse hub shim to Reverse gear idler shaft clearance Mainshaft end float Layshaft end float Lubricants Capacities Sealants REVISED 12 96 MANUAL GEARBOX 0 0 NEW 0 5 mm 0 02 in 0 05 0 20 mm 0 002 0 008 in 0 04 0 24 mm 0 0016 0 0083 in 0 11 0 21 mm 0 004 0 0083 in 0 005 0 055 mm 0 002 0 022 in 0 04 0 38 mm 0 0016 0 015 in 0 01 0 06 mm 0 0004 0 0024in 0 01 0 06 mm SERVICE LIMIT 0 327 mm 0 013 in 0 337 mm 0 13 in 0 337 mm 0 13 in 0 055 mm 0 022 in 0 38 mm 0 015 in 0 0
20. bolts washers and mounting rubbers securing bracket to extension housing 5 Tighten all bolts to 30 Nm OVERHAUL 37 MANUAL GEARBOX Bias spring adjustment Type A gearbox Bias spring adjustment Type B gearbox NOTE The purpose of this adjustment is to set both bolts so that the bias spring legs apply equal pressure on both ends of the gear lever cross pin when third or fourth gear is engaged This will ensure that when the lever is in neutral the gear change mechanism is automatically aligned for third or fourth gear 4 SO al N WAN E AK N 3 d l 4 il 37M7109 OZE Slacken bias adjustment plate bolts Select 2 md fourth gear and move lever fully to the right Me SES Tighten adjustment plate bolts 3 Check adjustment is correct by selecting third and fourth gears 37M7108 Select third or fourth gear Adjust the two adjusting screws until both legs of the spring are approximately 0 5 mm clear of the cross pin in the gear lever 3 Apply a light load to the gear lever in a left hand direction and adjust the right hand adjusting screw downward until the right hand spring leg just makes contact with the cross pin 4 Repeat the same procedure for the left hand adjusting screw 5 Lower both adjusting screws equal amounts until the radial play is just eliminated 6 Tighten locknuts 7 Return gear lever to neutral position and rock across the
21. e gear synchromesh 16 Selective spacers mainshaft amp layshaft end float 17 Selective spacer 5th gear reverse hub 12 96 DESCRIPTION AND OPERATION 1 MANUAL GEARBOX 37M7113A 44 2 DESCRIPTION AND OPERATION REVISED 12 96 GEARBOX COMPONENTS GEARS AND SHAFTS 3rd 4th gear selector fork Interlock spool 1st 2nd gear selector fork Selector shaft yoke pins Selector shaft Reverse 5th gear selector fork Selector quadrant Type A gearbox Selector yoke Type B D gearbox Selector yoke Type C gearbox 10 Input shaft front taper bearing 11 Input shaft 12 4th gear synchro ring 13 Pilot taper bearing 14 Spacer 15 3rd 4th gear synchro hub and sleeve 16 3rd gear synchro rings 17 3rd gear 18 Needle roller bearings 19 Mainshaft output shaft 20 Roll pin 21 Needle bearing 22 2nd gear 23 2nd gear synchro rings 24 2nd 1st gear synchro hub and sleeve 25 1st gear synchro rings 26 1st gear 27 Needle roller bearing 28 Bush JO Om ch REVISED 12 96 MANUAL GEARBOX Mainshaft taper bearing Selectable shims Selectable washer Bush Needle roller bearing Reverse gear Reverse gear synchro ring Reverse 5th gear synchro hub and sleeve Circlip Needle roller bearings 5th gear synchro ring bth gear bth gear segments 5th gear segment retaining ring Mainshaft rear support bearing Layshaft support beari
22. ector rod yoke Pinch bolt Bottom cover plate Remote gear change bracket Ball pin Ball pin seating Selector rod Selector rod bush MANUAL GEARBOX 0 0 Spacer Mounting rubbers Flexible mounting Bias spring Bridge plate liner Bias spring bridge plate Gear lever Gear lever cap Plunger Anti rattle spring DESCRIPTION AND OPERATION 11 MANUAL GEARBOX 37M0622 18 12 DESCRIPTION AND OPERATION TRANSFER BOX SELECTOR HOUSING TYPE A GEARBOX Gaiter retaining bolt Gaiter Gaiter support plate Gasket plate Gaskets Spring clip Clevis pin Circlip retaining nylon seat Gear lever ball MANUAL GEARBOX 0 0 Nylon seat Cross shaft Gear lever Selector housing Bushes Countersunk screws End cover Selector fork O rings DESCRIPTION AND OPERATION 13 MANUAL GEARBOX GEAR BOX DISMANTLE Service repair no 37 20 04 Clutch housing Type A gearbox Remove 2 Remove 2 bolts securing release lever pivot post remove post 3 Remove 6 bolts securing clutch housing to 37M7047 gearbox remove housing NOTE Dowel located A 1 Iffitted remove and discard clips retaining clutch release bearing pads remove bearing and clutch release lever recover pads OVERHAUL 1 MANUAL GEARBOX Clutch housing Type B gearbox Remove 3 M0494 1 Remove clutch release bearing 2 Remove b
23. ector shaft pin to selector shaft fit and tighten a new self locking nut 15 Fit output flange to output shaft 16 Fit new O ring and spacer a 17 Fit new tab washer 37M7103 2 18 Fit output flange bolt and tighten to 90 Nm 19 Lock bolt with tab washer 6 Using LRT 37 015 and LRT 37 21 press on mainshaft oil seal collar OVERHAUL 33 MANUAL GEARBOX Extension housing Type D gearbox Refit EP 37M7129 A aa NN 5 Apply Hylosil RTV 102 and fit extension case spool retainer fit and tighten bolt to 8 Nm Selector quadrant Type A gearbox Refit 37M7128 1 Remove all slave bolts from centre plate 2 Refit oil filter 3 Apply Hylosil RTV 102 to mating surfaces and fit extension housing Ensure that oil pipe locates in filter and that roller bearings are not dislodged CAUTION Do not use force If necessary remove extension housing and re align oil pump drive 4 Bolt extension housing to centre plate and main casing 37M7104 1 Position selector quadrant to selector shaft 2 Apply Loctite 270 to thread of a new setscrew Fit and tighten screw to 25 Nm 3 Move selector shaft to neutral position CAUTION Ensure end of setscrew locates N in hole in selector shaft 34 OVERHAUL MANUAL GEARBOX 0 0 Gear change lever yoke Type B gearbox Refit Gear change lever yoke Type D gearboxes I Refit 37M7105 37M7130 1 Position gea
24. fitted to yoke balls with multi purpose grease Type D gearboxes is not repairable item It 3 Fit yoke to selector rod fit and tighten pinch must be renewed if it is found to be bolt excessively worn 4 Assemble anti rattle spring and plunger to gear lever 5 Fit gear lever ensuring ball pin is located in yoke and anti rattle spring and plunger are not displaced 6 Fit gear lever cap fit and tighten bolt NOTE Do not fit bottom cover plate at this A stage 7 Slacken bias spring adjustment bolt locknuts 8 Fit bias spring bridge plate liners and bridge plates 9 Fit and tighten bolts and countersunk screws NOTE Final adjustment of bias spring is carried out after remote gear change is fitted to gearbox OVERHAUL 19 MANUAL GEARBOX Transfer box selector housing Type A gearbox Overhaul Dismantle 37M0618 1 Slide gaiter off gear lever 2 Remove 4 bolts securing gaiter support plate and gate plate 3 Remove gaiter support plate and gate plate discard gaskets 37MO619 4 Remove and discard spring clip retaining selector fork clevis pin 5 Remove clevis pin from selector fork remove and discard 2 bushes 20 OVERHAUL 37M0620 6 Remove and discard circlip retaining nylon ball seating 7 Remove gear lever recover nylon seating and ball 37M0544 8 Remove 2 countersunk head screws securing end cover to housing 9 Remove end cover remove and discard 2 O rings
25. gate several times The gear lever 37M7110 should return to the third and fourth gate Na 4 Fit sealing rubber to gear change housing apply Hylogrip 640 to screws and fit cover 38 OVERHAUL Bias spring adjustment Type C gearbox NOTE The purpose of this adjustment is to ensure that when bias spring is correctly adjusted the gear change mechanism is automatically aligned for 3rd or 4th gear selection when gear lever is in neutral 37M7111 1 Adjust both bias spring adjustment bolts until a clearance of 0 05mm exists between both legs of bias spring and gear lever cross pin 2 Apply a light load to move gear lever to the left and adjust right hand bolt until right hand leg of bias spring just contacts gear lever cross pin 3 Move gear lever to the right and adjust left hand bolt 4 Check that with gear lever moved fully to the left and right spring legs just contact gear lever cross pin 5 Select neutral then rock gear lever across the gate when released lever should return to 3rd 4th position 6 Tighten adjusting bolt locknuts MANUAL GEARBOX 0 0 Clutch housing Type A gearbox Refit 37M7112 1 Position clutch housing to gearbox 2 Fit securing bolts NOTE The 12 x 45mm bolts must be fitted A through locating dowels 3 Tighten bolts by diagonal selection to 72 Nm 4 Fit pivot post fit and tighten bolts 5 Apply lithium based grease to pivot post pads and push rod 6 Pos
26. ing dowel positions 3 Tighten bolts by diagonal selection to 72 Nm 4 Apply lithium based grease to pivot post 5 Fit pivot post and secure with two bolts
27. ition pads to clutch release lever fit release bearing 7 Fit new clips to retain pads NOTE Clips may become displaced in A service with no loss of performance 8 Fit release lever 9 Apply lithium based grease to splines of input shaft OVERHAUL 39 MANUAL GEARBOX Clutch housing Type B gearbox Refit 37M0616 1 Position clutch housing to gearbox 2 Fit securing bolts NOTE The 12 x 45mm bolts must be fitted AN through locating dowels 3 Tighten bolts by diagonal selection to 72 Nm 4 Apply lithium based grease to pivot post release lever socket and push rod 5 Fita new C clip to pivot post fit post 6 Fit spring clip to release lever fit but do not tighten bolt 40 OVERHAUL 7 Position release lever to pivot post ensuring spring clip is located behind C clip tighten bolt 8 Fit clutch release bearing and retain using new clips NOTE Clips may become displaced in A service with no loss of performance Clutch housing Type C gearbox Refit 1 Position clutch housing to gearbox 2 Fit securing bolts NOTE The 2 longest bolts must be fitted A at locating dowel positions 3 Tighten bolts by diagonal selection to 72 Nm 4 Apply lithium based grease to pivot post 5 Fit release lever and clutch release bearing Adaptor housing Type D gearbox Refit 1 Position adaptor housing to gearbox 2 Fit securing bolts NOTE The two longest bolts must be fitted at locat
28. ller bearing Remove circlip securing 5th gear synchromesh hub Rotate selector spool clear of synchro hub fork and remove 5th and reverse synchromesh hub assembly complete with fork and spool Remove mainshaft reverse gear complete with needle roller bearing and bush noting selectable spacer between reverse gear bush and centre plate bearing Remove layshaft reverse gear 14 Remove centre plate detent plug spring and ball 15 Remove 2 bolts securing spool retainer remove retainer 16 Remove slave bolts OVERHAUL 9 MANUAL GEARBOX Mainshaft and layshaft Remove Mainshaft Dismantle 1 Align selector shaft pin with slot in centre plate and using wooden blocks and hide mallet drive off centre plate 2 Collect detent ball and spring remove bearing tracks and shims 37M7065 1 Using LRT 99 002 and support bars under ist gear press mainshaft support bearing from mainshaft 3 Remove layshaft mainshaft and selector shaft from casing as complete unit 4 Remove input shaft and 4th gear baulk ring If not already removed with mainshaft 10 OVERHAUL MANUAL GEARBOX 37M7066 5 Remove spacer 3rd 4th gear synchromesh selector hub synchromesh baulk rings 3rd gear and needle bearing 37M7067 2 Remove 1st gear bush needle bearing and synchromesh baulk rings 3 Remove 1st 2nd gear synchromesh selector hub 2nd gear synchromesh baulk rings second gear and needle bearing 4
29. nd 37M7080 2 Using tool LRT 99 004 and LRT 37 004 remove pilot bearing track NOTE Ensure that the bearing is A supported by the lip inside LRT 37 001 37M7081 3 Using LRT 37 001 and LRT 99 002 remove taper roller bearing 4 Support the shaft under LRT 99 002 and press in a new pilot bearing track a EN 37M7082 5 Using LRT 99 002 Collets LRT 37 001 and adapter LRT 37 002 fit a new taper bearing MANUAL GEARBOX Mainshaft Inspection 37M7083 Examine bearing journals for wear and scores 2 Examine splines for wear and damage 3 Use an air line to check that the main oil feed from pump and feed to spigot bearing are clear 4 Check oil feed holes to roller bearing are clear OVERHAUL 23 MANUAL GEARBOX Layshaft Overhaul 1 Using extractor tool LRT 99 002 and collets LRT 37 022 withdraw layshaft bearings 2 Examine layshaft for wear and damage NOTE Layshaft and layshaft 5th gear fitted to later gearboxes are machined to enable fitment of a split washer to prevent gear movement on shaft The modified layshaft gear and split washer may be fitted to early gearboxes as an assembly 37M7084 3 Using press LRT 99 002 and support bars fit new taper roller bearings 24 OVERHAUL 37M7085 Mainshaft Reassembly 1 2 Clamp mainshaft in protected vice jaws output end upwards Fit 2nd gear needle roller bearing 2nd gear and synchromesh baulk rings on
30. ng Layshaft Layshaft support bearing Selectable shims Layshaft reverse gear Layshaft 5th gear Split washer later gearboxes bth gear nut Layshaft rear support bearing Spacer Reverse idler gear Needle roller bearing Reverse idler shaft DESCRIPTION AND OPERATION 3 MANUAL GEARBOX 37M7114 REVISED 12 96 DESCRIPTION AND OPERATION 4 GEARBOX CASINGS Front cover Input shaft oil seal Oil level plug Washer Oil drain plug Gearcase Spool retainer Centre plate Locating dowels Selector plug outer detent ball and spring Splash shield Extension housing Types A and B gearbox Gate plate Spool retainer Extension housing Inhibitor cam spring Inhibitor cam Inhibitor cam shaft Oil selector collar Oil seal Oil pump O ring Reverse light switch Oil cooler by pass Bolt O ring Oil pick up pipe MANUAL GEARBOX 0 0 Oil filter Oil pick up ring Oil cooler adaptor Bolt O ring Extension housing Type C gearbox Gate plate Type C gearbox Inhibitor cam end plate Type C gearbox Spool retainer Type C gearbox Selector shaft oil seal Type C gearbox Spacer Type C gearbox Speedometer pinion Type C gearbox Oil seal Type C gearbox Output shaft drive flange Type C gearbox O ring Type C gearbox Spacer Type C gearbox
31. olt securing spring clip to clutch release lever remove clip 3 Remove clutch release lever 4 Remove C clip from release lever pivot post discard clip 5 Remove 6 bolts securing clutch housing to gearbox remove housing NOTE Dowel located 2 OVERHAUL Clutch housing Type C gearbox Remove 37M0495 1 Pull clutch release lever off pivot post remove lever and clutch release bearing 37M0496 2 Remove 6 bolts securing clutch housing to gearbox remove clutch housing NOTE 2 longest bolts are fitted at dowel locations and have plain washers under their heads MANUAL GEARBOX Gear change selector housings Type A gearbox Remove Clutch housing Type D gearbox Remove 37M7119 37M7049 NOTE Type D gearboxes have a standard clutch housing adaptor which mates with both V8 and diesel engine clutch 1 housings The above illustration shows the Se securing gearenangs housing gearbox removed at the clutch housing adaptor with the clutch housing adaptor containing the NOTE Dowel located clutch mechanism still fitted to the engine 75 Remove 4 bolts securing transfer box selector housing remove housing 37M7120 1 Remove 2 bolts securing release lever pivot post Remove post 2 Remove 6 bolts securing adaptor housing to gearbox Remove adaptor housing OVERHAUL 3 MANUAL GEARBOX Remote housing Type A gearbox Remove 37M7050 37M7052 1
32. orque wrench setting figures given in this Manual must be used Locking devices where specified must be fitted If the efficiency of a locking device is impaired during removal it must be renewed The Terms of the vehicle Warranty may be invalidated by the fitting of other than Rover Land Rover recommended parts All Rover Land Rover recommended parts have the full backing of the vehicle Warranty Rover Land Rover Dealers are obliged to supply only recommended parts INTRODUCTION 1 INTRODUCTION SPECIFICATION Rover Land Rover are constantly seeking to improve the specification design and production of their vehicles and alterations take place accordingly While every effort has been made to ensure the accuracy of this Manual it should not be regarded as an infallible guide to current specifications of any particular component or vehicle This Manual does not constitute an offer for sale of any particular component or vehicle Rover Land Rover Dealers are not agents of Rover Land Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation 2 INTRODUCTION GEARBOX IDENTIFICATION The procedures given in this manual cover overhaul of the R380 gearbox fitted to a range of vehicles and as such certain differences exist between gearboxes particularly in respect of the extension housings gear change housings and transfer box selector housings It is important therefore that
33. ply Hylogrip 640 and refit shaft 12 14 Fit new mainshaft support bearing Fit new mainshaft rear oil seal using tool LRT 37 014 Fit new Layshaft support bearing Fit new oil pick up ring Align tag with centre of drain slot Examine gate plate and renew if worn or damaged Refit reverse light switch with new copper washer Tighten to 24 Nm Refit reverse inhibition cam and spring Refit oil pipe bend uppermost OVERHAUL Gear change selector housings Overhaul Gear change housing Type A gearbox Dismantle 37M0534 Using a suitable piece of tubing release both ends of bias spring from ball pins Slacken locknuts and remove bias spring adjusting screws Drift out roll pin remove bias spring 37M0535 4 Remove extension from lower gear lever 5 Remove bolt and special washer securing lower gear lever 6 Carefully withdraw lower gear lever from housing ensuring that spring loaded nylon pad is retained during removal WARNING Personal injury may result if A pad is not retained 7 Release nylon pad recover spring 8 Clean all components MANUAL GEARBOX 0 0 Inspection 1 Check lower gear lever ball pin for wear replace if necessary CAUTION If lower gear lever is to be replaced then ball pin seating located in remote housing should also be replaced 2 Check nylon pad and spring for wear and damage replace if necessary 3 Check bias
34. r change lever yoke on selector shaft with ball facing towards output shaft 1 Position gear lever yoke on selector shaft with 2 Apply Loctite 270 to threads of a new setscrew ball facing towards output shaft fit and tighten screw to 25 Nm 2 Apply Loctite 270 to threads of new setscrew Fit and tighten screw to 25 Nm CAUTION Ensure end of setscrew locates A in hole in selector shaft CAUTION Ensure end of setscrew locates AN in hole in selector shaft OVERHAUL 35 MANUAL GEARBOX Remote housing Type A gearbox Refit 1 Apply Hylosil RTV 102 to mating surfaces and fit to extension housing 2 Position remote housing to extension housing and gearcase ensuring rollers locate in quadrant 37M7106 3 Fit but do not fully tighten 3 bolts in positions shown Transfer box selector housing Type A gearbox Refit 1 Smear a new gasket with grease and fit to remote housing 2 Position transfer box selector housing to remote housing 3 Fit but do not fully tighten 4 bolts 36 OVERHAUL Gear change housing Type A gearbox Refit 1 Smear a new gasket with grease and fit to remote housing 2 Position gear change housing to remote housing ensuring gear lever ball is correctly located 3 Fit but do not fully tighten 4 bolts 4 Tighten remote housing transfer box selector housing and gear change housing bolts to 25 Nm Transfer box selector housing Type B gearbox Refit 1 Smear a new gasket with
35. spring roll pin for damage replace if necessary Reassemble 1 Smear ball pin with multi purpose grease and fit spring and nylon pad 2 Depress nylon pad against spring pressure position lower gear lever in housing CAUTION Ensure nylon pad is facing N away from bias spring location 3 Fitlower gear lever retaining bolt and special washer tighten bolt to 15 Nm Fit extension to lower gear lever Position roll pin to housing fit roll pin Fit bias spring adjusting screws and locknuts Using a suitable piece of tubing locate both ends of bias spring over ball pins No of NOTE Do not adjust bias spring at this A stage OVERHAUL 15 MANUAL GEARBOX Remote housing Type A gearbox Dismantle 37M7072 1 Remove setscrew securing trunnion to selector 6 shaft remove trunnion 2 Remove and discard circlip securing ball pin 7 seating to trunnion remove seating 3 Slacken locknut remove 5th gear stop screw 8 A 1 16 OVERHAUL 37M7073 Remove blanking plug from end of remote housing Remove setscrew securing quadrant to selector shaft remove quadrant Remove selector shaft from remote housing remove and discard O ring Remove and discard circlip retaining rollers and pin to quadrant Remove pin recover rollers CAUTION Retain shim s Inspection Check selector shaft and bore in remote housing for wear 2 Check quadrant rollers and pin for
36. the mainshaft and the layshaft has to be determined before the gear box can be reassembled This is achieved by clamping the mainshaft and layshaft separately between the centre plate and main casing and measuring the movement on each shaft with a Dial test indicator The end float setting for the mainshaft and layshaft is 0 01 0 06mm 0 0004 0 0024in Shims to make up the required clearances are placed under the bearing tracks of the centre plate Shimming b Fit bearing tracks to main casing front cover 2 Fit front cover to casing without oil seal 3 Clamp casing in vice with front cover downwards Fitinput shaft Do not fit 4th gear baulk ring Fit mainshaft assembly to input shaft Fit mainshaft bearing shim and track to centre plate oca MANUAL GEARBOX 0 0 Assembling mainshaft and layshaft to centre plate 1 Secure centre plate to workstand 2 Fit selected shims and bearing tracks 3 Fit inboard detent ball and spring use a dummy bar to temporarily hold the ball in place 37M7093 7 Fit centre plate and bolt down using 8 slave bolts 8 Fit large ball bearing to rear of mainshaft 9 Mount dial test indicator 10 Rotate mainshaft to settle bearings 11 Lift mainshaft and note reading 12 Dismantle and substitute shims if reading 37M7094 incorrect 13 Repeat procedure lt 14 Remove mainshaft assembly and repeat 4 Check both synchromesh units are in neu
37. to mainshaft Rotate each baulk ring to ensure they locate onto each other Assemble the 1st and 2nd synchromesh selector hub onto mainshaft spline note 2nd speed side marking Ensure that baulk ring has located correctly inside hub Rotate the ring slightly as the hub is lowered Fit 1st gear synchromesh baulk rings needle roller bearing 1st gear and bush onto mainshaft ensuring baulk rings locate correctly inside selector hub Using LRT 99 002 bearing guide LRT 37 019 collets LRT 37 001 and adaptor LRT 37 002 press on mainshaft taper roller bearing taking care not to disturb the lay of the synchromesh baulk rings and gears MANUAL GEARBOX 0 0 6 Check the end float of the 1st and 2nd gear assembly using a feeler gauge between the gear and mainshaft bearing Maximum clearance 1st gear 0 05 0 20mm 0 002 0 008 in 2nd gear 0 04 0 21mm 0 0016 0 0083 in Invert mainshaft in vice and fit 3rd gear needle roller bearing third gear and synchromesh baulk rings 8 Assemble 3rd 4th gear synchromesh selector hub note 3rd speed side markings onto mainshaft splines taking care to locate the baulk rings into recesses in the selector hub 9 Fit spacer OVERHAUL 25 MANUAL GEARBOX Em INN T UTN ess BAN J Y ON aaa See N LI 37M7086 10 Using LRT 99 002 press
38. tral procedure for layshaft and fit selector shaft assembly to mainshaft 15 Dismantle assembly in preparation for 5 Fit mainshaft and selectors as complete unit to assembly on stand centre plate aligning pin with slot in plate 6 Fit 4th gear synchromesh baulk ring OVERHAUL 29 MANUAL GEARBOX SSE 4 NG Montre 2 37 7095 7 Fit layshaft whilst lifting mainshaft to clear layshaft rear bearing 8 Lubricate pilot bearing and fit input shaft 30 OVERHAUL X Wi NN 37M7096 EG 9 Fit oil seal to front cover Ensure seal is fitted down to shoulder Apply Hylosil RTV 102 to front cover as shown NOTE Early type seal unwaxed lubricate seal with gearbox oil Later type seal wax coated fit seal dry Fit bearing tracks and clips to main case and fit front cover Seal fixings with Hylogrip 640 Apply Hylosil RTV 102 and fit main casing to centre plate Bolt casing and centre plate together using 2 or 3 slave bolts Fitnew O ring and fit spool retainer Remove casing from stand and clamp in vice MANUAL GEARBOX Reverse and 5th gear Reassembly 37M7098B NOTE Bevelled side of washer must face 1 Fit mainshaft reverse gear selectable washer A towards gear bush and needle bearing 2 Fit mainshaft reverse gear and synchromesh 9 Fit new mainshaft thrust collar roll pin Locate baulk ring 5th gear thrust segments and retaining ring 3 Fit la
39. using 25 Nm Upper gear lever assembly to lower gear lever 25 Nm Yoke to selector shaft 25 Nm Filler plug 30 Nm Oil level plug 30 Nm Oil drain plug 50 Nm Clutch housing to gearbox 72 Nm Output flange bolt 90 Nm 5th gear layshaft stake nut 220 Nm REVISED 12 96 TORQUE WRENCH SETTINGS 1 SERVICE TOOLS MANUAL GEARBOX 0 0 NOTE Where the use of special tools is specified only these tools should be used to avoid the possibility of personal injury and or damage to components Land Rover Number LRT 37 001 LRT 37 002 LRT 37 004 LRT 37 009 LRT 37 010 LRT 37 014 LRT 37 015 LRT 37 021 LRT 37 022 LRT 37 023 LRT 37 024 LRT 51 003 LRT 99 002 LRT 99 004 Rover Number 18G47BA 18G47BAX 18G284AAH 18G705 18G705 1A 18G1422 18G1431 1861205 547 186284 Service tools must be obtained direct from the manufacturers V L Churchill P O Box No 3 London Road Daventry Northants NN11 4NF England Description Adaptor input shaft bearing Conversion kit Adaptor for input shaft pilot bearing track Puller bearing and oil seal collar remover Adaptor for mainshaft oil seal collar Mainshaft rear oil seal replacer Mainshaft rear support bearing track and oil seal collar replacer Adaptor for mainshaft rear support bearing track and oil seal collar replacer Adaptor for layshaft bearings Layshaft holding tool Rear mainshaft bearing track remover
40. yshaft reverse gear 4 Assemble selector spool selector fork and reverse 5th gear synchromesh hub Fit as one assembly to mainshaft splines and selector shaft Ensure synchromesh baulk ring locates inside hub 5 Fit new circlip NOTE The fit of the circlip is controlled by the selectable washer behind the reverse gear Adjust to 0 005 0 055mm 0 0002 0 0021in 37M7099 6 Fit 5th gear split needle bearing 7 Fit 5th gear and 5th gear synchromesh baulk ring to mainshaft fit layshaft Sth gear 10 Using LRT 37 023 to hold layshaft 5th gear 8 Later gearboxes Fit split washer to retain tighten the layshaft 5th gear nut to 220 Nm layshaft 5th gear 11 Stake layshaft 5th gear nut OVERHAUL 31 MANUAL GEARBOX 12 gt 37M7100 12 Using tool LRT 37 015 and LRT 37 021 press mainshaft rear support bearing track to collar on mainshaft 13 Apply small amount of heat and fit layshaft rear support bearing 37M1206A 14 Fit centre plate detent ball and spring 15 Fit and tighten plug to 25 Nm NOTE Patchlok plug may be re used provided threads are undamaged 16 Move selector shaft and check that detent balls can be felt to engage in detent 32 OVERHAUL Extension housing Type A and B Gearbox Refit 1 Remove all slave bolts from centre plate and casing 2 Refit oil filter fi gt D NA AA JE I m 11 M SS
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