Late 2A lay shafts without the circlip groove are stronger than the early ones. Then I got several requests to add other alternative gearboxes available used in the North American market. Registration is quick and easy and will give you full access to the site and allow you to ask questions or make comments and join in on the conversation. Fit bias spring adjusting screws and locknuts. Remove 12mm bolt from end of mainshaft. This blocks the synchro assembly.
The sleeves are further identified with a series of half moon notches which clearly identify which side of the assembly faces which gear. I think I have a problem with the selector shaft on our D2 Td5 and I'm wondering if anyone has had similar problems. Me I'd fit the gearbox to the chassis. If you would like to discuss any of the contents, or just say hi, please feel free to. Fit clutch release bearing and retain using new clips. 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.
When you fit a new gearbox this can sometimes need adjusting to agree with the selector shafts to ensure a clean gearshift. My Defender is a bit of an oddity. Tighten bolts by diagonal selection to 72 Nm. This gate position must be adjusted correctly to agree with the selectors in the gearbox to ensure a good gearshift. The R380 gearbox was fitted to all Land Rover Defenders from 1994 until 2006.
Check speedometer pinion for wear and damage. While applying light pressure to gear lever towards left, turn screw clockwise until it contacts yoke. Maximum clearance: 1st gear: 0. The syncros must come to a stop when the shifter goes through the neutral position if the syncros are to last. Apply lithium based grease to pivot post. Fit bolts and tighten to 25 Nm. The gearbox is in exactly the same place as the older models.
Thanks for the input guys - I really appreciate it. Friction surfaces synchronise the shaft speeds, and synchromesh and gear lock together. Remove bolt securing spring clip to clutch release lever, remove clip. There are three possible problems. Fit new mainshaft thrust collar roll pin.
Most modern cars have synchromesh on all forward gears, but on earlier cars it is not provided on first gear. He used some or other synthetic stuff that he says made his box also R380 sound and feel so much better. The nylon cage at the end of the selector rail can swell when hot, and cause friction. Noting fitted positions of mounting rubbers and washers, Rremove 2 bolts securing remote gear change to extension housing, recover washers and mounting rubbers. Adaptor housing - Type D gearbox - Refit 1.
I don't really have adverts here: it's funded by wonderful people buying. The gears are selected by a system of rods and levers operated by the gear lever. Fit 4th gear synchromesh baulk ring. Other principal changes were to the reverse idler gear, bearing and shaft and the syncro units. Overhaul operations in this manual list the applicable gearbox type referred to and it is important that the relevant operation is followed. There is a very rare, short bellhousing R380 that was intended to retrofit to 200Tdi's.
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. Remove and discard oil seal. Check that threads of detent plug are not damaged. Items numbered in the illustrations are referred to in the text. Slacken locknuts and remove bias spring adjusting screws. Remove gear lever, recover anti-rattle spring and plunger.
Position gear lever yoke on selector shaft with ball facing towards output shaft. Lubricate replacement ball and seating with multi - purpose grease and press into yoke; secure using new circlip. Position gear change housing to remote housing ensuring gear lever ball is correctly located. Fit 2nd gear needle roller bearing, 2nd gear and synchromesh baulk rings onto mainshaft. At this time I'm leaning towards somewhere around 55:1 as being the best overall low range ratio for use in many different situations with 32 - 34 inch dia tyres.
Remove 6 bolts securing clutch housing to gearbox, remove housing. Insert suitable blocks of wood between extension housing and centre plate and carefully lever extension housing away until drive gear is released. Fit new oil pick-up ring Align tag with centre of drain slot. The minimum clearance should be 0. It is also known as the Spanish Box. Type C gearbox - As for A and B Types and including the following: 12.