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Land Rover R380 Manual 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 Discovery 2.
This manual contains procedures for overhaul of the R380 gearbox or R380 Borg-Warner Transfer Case 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.
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.
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.
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.
Contents:
DATA [ GENERAL DATA ]
TORQUE WRENCH SETTING [ TORQUE WRENCH SETTINGS ]
SERVICE TOOLS [ SERVICE TOOLS ]
DESCRIPTION AND OPERATION [ DESCRIPTION GEARBOX COMPONENTS-GEARS AND SHAFTS GEARBOX CASINGS GEAR CHANGE HOUSING - TYPE A GEARBOX GEAR CHANGE HOUSING - TYPE B GEARBOX REMOTE GEAR CHANGE HOUSING - TYPE C GEARBOX TRANSFER BOX SELECTOR HOUSING - TYPE A GEARBOX ]
OVERHAUL
GEARBOX DISMANTLE [ Clutch housing - Type A gearbox - Remove Clutch housing - Type B gearbox - Remove Clutch housing - Type C gearbox - Remove Clutch housing - Type D gearbox - Remove Gear change/selector housings - Type A gearbox - Remove Remote housing - Type A gearbox - Remove Gear change/selector housings - Type B gearbox - Remove Selector quadrant - Type A gearbox - Remove Gear change lever yoke - Type B gearbox - Remove Remote gear change - Type C gearbox - Remove Remote gear change - Type D gearbox - Remove Gear change lever yoke - Type D gearbox - Remove Extension housing - Types A and B gearbox - Remove Extension housing - Type C gearbox - Remove Extension housing - Type D gearbox - Remove 5th and Reverse gear - Remove Output shaft and layshaft - Remove Output shaft - Dismantle Gearcase Front Cover - Remove Front Cover - Early type - Dismantle Front Cover - Later type - Dismantle Centre plate - Dismantle Extension housings - Overhaul Gear change/selector housings - Overhaul Synchromesh assemblies - Overhaul Checking baulk ring clearances Input shaft - Overhaul Output shaft - Inspection Layshaft - Overhaul Output shaft - Reassemble Reverse idler gear and centre plate - Reassemble Selectors - Inspection Selectors - Reassemble ]
GEARBOX REASSEMBLE [ Output shaft and layshaft end float Shimming Assembling output shaft and layshaft to centre plate Reverse and 5th gear - Reassemble Extension housing - Type A and B Gearbox - Refit Extension housing - Type C gearbox - Refit Extension housing - Type 0 gearbox - Refit Selector quadrant - Type A gearbox - Refit Gear change lever yoke - Type B gearbox - Refit Gear change lever yoke - Type 0 gearbox - Refit Remote housing - Type A gearbox - Refit Transfer box selector housing - Type A gearbox - Refit Gear change housing - Type A gearbox - Refit 5th gear stop screw adjustment - Type A gearbox Transfer box selector housing - Type B gearbox - Refit Gear change housing - Type B gearbox - Refit Remote gear change - Type C gearbox - Refit Remote gear change - Type 0 gearbox - Refit Bias spring adjustment - Type A gearbox Bias spring adjustment - Type B gearbox Bias spring adjustment - Type C gearbox Clutch housing - Type A gearbox - Refit Clutch housing - Type B gearbox - Refit Clutch housing - Type C gearbox - Refit Adaptor housing - Type 0 gearbox - Refit ]
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