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
Discovery 2

Publication Part No.LRL 0003ENG - 3rd Edition

 Land Rover 2000

All rights reserved. No part of this publication may be

reproduced, stored in a retrieval system or
transmitted in any form, electronic, mechanical,
recording or other means without prior permission
from Land Rover.
 INTRODUCTION

CONTENTS Page

INTRODUCTION
INTRODUCTION ...................................................................................................... 1
REPAIRS AND REPLACEMENTS ........................................................................... 1
SPECIFICATION ...................................................................................................... 2
GEARBOX IDENTIFICATION ................................................................................... 2
 INTRODUCTION

INTRODUCTION References

How to use this manual Operations covered in this manual do not include
reference to testing the vehicle after repair. It is
To assist in the use of this manual the section title is essential that work is inspected and tested after
given at the top and the relevant sub - section is completion and if necessary, a road test of the
given at the bottom of each page. vehicle is carried out, particularly where safety
related items are concerned.
This manual contains procedures for overhaul of the
R380 gearbox on the bench with the clutch and, if Dimensions
applicable, the transfer box removed. For all other
information regarding Adjustments, Removal of oil The dimensions quoted are to design engineering
seals, clutch, transfer box and gearbox unit, consult specification with Service Limits where applicable.
the appropriate Repair Manual for the model
concerned.

This manual is divided into 5 sections, Data, Torque

Settings, Service Tools, Description and finally,
REPAIRS AND REPLACEMENTS
Overhaul.To assist filing of revised information each
sub - section is numbered from page 1.
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
The individual overhaul items are to be followed in
the sequence in which they appear. Items numbered
Attention is particularly drawn to the following points
in the illustrations are referred to in the text.
concerning repairs and the fitting of replacement
parts and accessories.
Overhaul operations include reference to Service
Tool numbers and the associated illustration depicts
Safety features embodied in the car may be
the tool in use. Operations also include reference to
impaired if other than Land Rover recommended
wear limits, relevant data, torque figures, and
parts are fitted. In certain territories, legislation
specialist information and useful assembly details.
prohibits the fitting of parts not to the manufacturer’s
specification.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
Torque wrench setting figures given in this Manual
must be used. Locking devices, where specified,
WARNING: Procedures which must be
must be fitted. If the efficiency of a locking device is
followed precisely to avoid the possibility
impaired during removal it must be renewed.
of injury.
The Terms of the vehicle Warranty may be
CAUTION: Calls attention to procedures
invalidated by the fitting of other than Land Rover
which must be followed to avoid damage
recommended parts. All Land Rover recommended
to components.
parts have the full backing of the vehicle Warranty.
NOTE: Gives helpful information.
Land Rover Dealers are obliged to supply only
recommended parts.

INTRODUCTION 1
INTRODUCTION

SPECIFICATION GEARBOX IDENTIFICATION

Land Rover are constantly seeking to improve the The procedures given in this manual cover overhaul
specification, design and production of their vehicles of the R380 gearbox fitted to a range of vehicles and
and alterations take place accordingly. While every as such, certain differences exist between
effort has been made to ensure the accuracy of this gearboxes, particularly in respect of the extension
Manual, it should not be regarded as an infallible housings, gear change housings and transfer box
guide to current specifications of any particular selector housings. It is important therefore that
component or vehicle. before starting work, the gearbox to be overhauled is
correctly identified. Identification can be made by
This Manual does not constitute an offer for sale of noting the gearbox serial number prefix stamped on
any particular component or vehicle. Land Rover the RH side of the gearbox casing and referring to
Dealers are not agents of Land Rover and have no the following table which lists four types of gearbox,
authority to bind the manufacturer by any expressed A, B, C and D together with their appropriate serial
or implied undertaking or representation. 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; 66A; 68A; 70A; 74A

Type B gearbox prefixes: - 53A; 55A; 63A; 67A;

69A; 73A

Type C gearbox prefix: - 18A

Type D gearbox prefixes: - 64A; 65A

2 INTRODUCTION
 MANUAL GEARBOX

CONTENTS Page

DATA
GENERAL DATA ...................................................................................................... 1

TORQUE WRENCH SETTING

TORQUE WRENCH SETTINGS .............................................................................. 1

SERVICE TOOLS
SERVICE TOOLS ..................................................................................................... 1

DESCRIPTION AND OPERATION

DESCRIPTION ......................................................................................................... 1
GEARBOX COMPONENTS - GEARS AND SHAFTS .............................................. 3
GEARBOX CASINGS ............................................................................................... 5
GEAR CHANGE HOUSING - TYPE A GEARBOX ................................................... 7
GEAR CHANGE HOUSING - TYPE B GEARBOX ................................................... 9
REMOTE GEAR CHANGE HOUSING - TYPE C GEARBOX ................................ 11
TRANSFER BOX SELECTOR HOUSING - TYPE A GEARBOX ........................... 13

OVERHAUL
GEARBOX DISMANTLE ........................................................................................... 1
Clutch housing - Type A gearbox - Remove ............................................................. 1
Clutch housing - Type B gearbox - Remove ............................................................. 2
Clutch housing - Type C gearbox - Remove ............................................................. 2
Clutch housing - Type D gearbox - Remove ............................................................. 3
Gear change/selector housings - Type A gearbox - Remove ................................... 4
Remote housing - Type A gearbox - Remove ........................................................... 4
Gear change/selector housings - Type B gearbox - Remove ................................... 5
Selector quadrant - Type A gearbox - Remove ......................................................... 6
Gear change lever yoke - Type B gearbox - Remove ............................................... 6
Remote gear change - Type C gearbox - Remove ................................................... 7
Remote gear change - Type D gearbox - Remove ................................................... 7
Gear change lever yoke - Type D gearbox - Remove ............................................... 8
Extension housing - Types A and B gearbox - Remove ........................................... 8
Extension housing - Type C gearbox - Remove ....................................................... 9
Extension housing - Type D gearbox - Remove ..................................................... 10
5th and Reverse gear - Remove ............................................................................. 11
Output shaft and layshaft - Remove ....................................................................... 13
Output shaft - Dismantle ......................................................................................... 14
Gearcase ................................................................................................................ 15
Front Cover - Remove ............................................................................................ 16
Front Cover - Early type - Dismantle ....................................................................... 16
Front Cover - Later type - Dismantle ....................................................................... 17
Centre plate - Dismantle ......................................................................................... 17
Extension housings - Overhaul ............................................................................... 18
Gear change/selector housings - Overhaul ............................................................ 19
Synchromesh assemblies - Overhaul ..................................................................... 27
Checking baulk ring clearances .............................................................................. 28
Input shaft - Overhaul ............................................................................................. 28
Output shaft - Inspection ......................................................................................... 29
Layshaft - Overhaul ................................................................................................. 30
Output shaft - Reassemble ..................................................................................... 31
MANUAL GEARBOX

CONTENTS Page
Reverse idler gear and centre plate - Reassemble ................................................. 33
Selectors - Inspection ............................................................................................. 33
Selectors - Reassemble .......................................................................................... 34
GEARBOX REASSEMBLE ..................................................................................... 34
Output shaft and layshaft end float ......................................................................... 34
Shimming ................................................................................................................ 34
Assembling output shaft and layshaft to centre plate .............................................. 35
Reverse and 5th gear - Reassemble ...................................................................... 37
Extension housing - Type A and B Gearbox - Refit ................................................ 39
Extension housing - Type C gearbox - Refit ........................................................... 40
Extension housing - Type D gearbox - Refit ........................................................... 40
Selector quadrant - Type A gearbox - Refit ............................................................. 41
Gear change lever yoke - Type B gearbox - Refit ................................................... 41
Gear change lever yoke - Type D gearbox - Refit ................................................... 42
Remote housing - Type A gearbox - Refit ............................................................... 42
Transfer box selector housing - Type A gearbox - Refit .......................................... 43
Gear change housing - Type A gearbox - Refit ....................................................... 43
5th gear stop screw adjustment - Type A gearbox .................................................. 44
Transfer box selector housing - Type B gearbox - Refit .......................................... 44
Gear change housing - Type B gearbox - Refit ....................................................... 45
Remote gear change - Type C gearbox - Refit ....................................................... 45
Remote gear change - Type D gearbox - Refit ....................................................... 46
Bias spring adjustment - Type A gearbox ............................................................... 46
Bias spring adjustment - Type B gearbox ............................................................... 47
Bias spring adjustment - Type C gearbox ............................................................... 47
Clutch housing - Type A gearbox - Refit ................................................................. 48
Clutch housing - Type B gearbox - Refit ................................................................. 48
Clutch housing - Type C gearbox - Refit ................................................................. 49
Adaptor housing - Type D gearbox - Refit ............................................................... 50
 MANUAL GEARBOX

GENERAL DATA

NEW SERVICE LIMIT

Baulk ring clearances 0.5 mm (0.02 in) 0.5 mm (0.02 in)

1st gear end float 0.05 - 0.20 mm

(0.002 - 0.008 in) 0.327 mm (0.012 in)

2nd gear end float 0.04 - 0.21 mm

(0.0016 - 0.008 in) 0.337 mm (0.013 in)

3rd gear end float 0.11 - 0.21 mm

(0.004 - 0.008 in) 0.337 mm (0.013 in)

Adjust 5th - reverse hub - shim to:- 0.005 - 0.055 mm

(0.0002 - 0.002 in) 0.055 mm (0.002 in)

Reverse gear idler shaft clearance 0.04 - 0.38 mm

(0.0016 - 0.015 in) 0.38 mm (0.015 in)

Output shaft end float

Early gearboxes:- 0.01 - 0.06 mm
(0.0004 - 0.0024in) 0.06 mm (0.0024 in)

Later gearboxes having letter K added

to gearbox serial number:- 0.00 - 0.05 mm
(0.00 - 0.002 in) 0.05 mm (0.002 in)

Layshaft end float

Early gearboxes:- 0.01 - 0.06 mm
(0.0004 - 0.0024 in) 0.06 mm (0.0024 in)

Later gearboxes having letter K added

to gearbox serial number:- 0.0 - 0.05 mm
(0.0 - 0.002 in) 0.05 mm (0.002 in)

GENERAL DATA 1
 MANUAL GEARBOX

TORQUE WRENCH SETTINGS

Oil pump to extension case 6 Nm (4.5 lbf.ft)

Attachment plate to gearcase 8 Nm (6 lbf.ft)
Attachment plate to remote housing 8 Nm (6 lbf.ft)
Splash shield bolts 8 Nm (6 lbf.ft)
Bottom cover to clutch housing 8 Nm (6 lbf.ft)
Breather baffle 8 Nm (6 lbf.ft)
Clip to clutch release lever 8 Nm (6 lbf.ft)
Cover to gear change housing* 8 Nm (6 lbf.ft)
Interlock spool retainer to gear case 8 Nm (6 lbf.ft)
Torsion spring locknut - adjusting screw 8 Nm (6 lbf.ft)
Screw - gear lever retention 8 Nm (6 lbf.ft)
Breather 15 Nm (11 lbf.ft)
Gear lever cap retainer bolt 15 Nm (11 lbf.ft)
Reverse inhibitor shaft 16 Nm (12 lbf.ft)
Reverse light switch 24 Nm (17 lbf.ft)
Transfer box to remote housing bolts 25 Nm (18 lbf.ft)
Bias adjustment plate bolts* 25 Nm (18 lbf.ft)
Selector quadrant setscrew* 25 Nm (18 lbf.ft)
Gear change lever yoke setscrew* 25 Nm (18 lbf.ft)
Bridge plates to gear change housing* 25 Nm (18 lbf.ft)
Extension case to gear case* 25 Nm (18 lbf.ft)
Front cover to gear case* 25 Nm (18 lbf.ft)
Gear change housing to extension case 25 Nm (18 lbf.ft)
Gear lever housing to remote housing 25 Nm (18 lbf.ft)
Guide - clutch release sleeve to clutch housing 25 Nm (18 lbf.ft)
Mounting bracket 25 Nm (18 lbf.ft)
Pivot clutch lever to clutch housing 25 Nm (18 lbf.ft)
Pivot plate to clutch housing 25 Nm (18 lbf.ft)
Plug - detent ball and spring* 25 Nm (18 lbf.ft)
Plunger housing to gear change housing 25 Nm (18 lbf.ft)
Remote selector housing to extension case 25 Nm (18 lbf.ft)
Slave cylinder to clutch housing 25 Nm (18 lbf.ft)
Upper gear lever assembly to lower gear lever 25 Nm (18 lbf.ft)
Yoke to selector shaft 25 Nm (18 lbf.ft)
Oil filler/level plug 30 Nm (22 lbf.ft)
Oil drain plug 50 Nm (37 lbf.ft)
Clutch housing to gearbox 72 Nm (53 lbf.ft)
Output flange bolt 90 Nm (66 lbf.ft)
5th gear layshaft stake nut 220 Nm (162 lbf.ft)
Remote housing blanking plug* 30 Nm (22 lbf.ft)
Selector shaft trunnion setscrew* 25 Nm (18 lbf.ft)
Transfer box gaiter support plate bolts 15 Nm (11 lbf.ft)
Gate plate bolts 15 Nm (11 lbf.ft)

* Apply Loctite 290 to threads

TORQUE WRENCH SETTINGS 1

 MANUAL GEARBOX

SERVICE TOOLS

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 Description

LRT-37-001/2 Adaptor for output shaft oil seal collar and bearing track
remover

LRT-37-004 Adaptor for input shaft pilot bearing track remover

LRT-37-009 Puller, bearing and oil seal collar remover

LRT-37-010 Adaptor for output shaft oil seal collar and bearing track

LRT-37-014 Output shaft rear oil seal replacer

LRT-37-015 Output shaft rear support bearing track and oil seal collar
replacer.

LRT-37-021 Adaptor for output shaft rear support bearing track and oil
seal collar replacer.

LRT-37-022 Adaptor for layshaft bearings

LRT-37-023 Layshaft holding tool

LRT-37-043 Adaptor for input shaft bearing

LRT-37-043/2 Adaptor

LRT-37-044 Adaptor for layshaft bearings

LRT-51-003 Flange holder

LRT-99-002 Hand press

LRT-99-004 Impulse extractor

SERVICE TOOLS 1
 MANUAL GEARBOX

DESCRIPTION

The R380 5 speed all synchromesh gearbox The input shaft, output shaft and layshaft are
comprises an input shaft, output shaft, layshaft and supported by taper roller bearings with all gears
reverse idler shaft . running on caged needle roller bearings. Output
shaft and layshaft bearings end float is controlled by
Gearbox casings consist of a front cover, gearcase, selective thrust washers located in the centre plate.
centre plate and extension housing, all casings are
located by dowels and sealed. Lubrication is by an oil pump located in the
extension housing which directs oil via internal
Selector forks for 1st/2nd and 3rd/4th gears are drillings in the output shaft to lubricate the
located on a single selector shaft inside the main components.
gearcase whilst the selector fork for fifth and reverse
gear is located on the same selector shaft inside the
extension housing.

1. Output shaft 1st gear 10. Breather

2. Output shaft 2nd gear 11. Single rail gear selector
3. Output shaft 3rd gear 12. 1st/2nd synchromesh
4. Input shaft/4th gear 13. Oil seals
5. Output shaft 5th gear 14. 3rd/4th gear synchromesh
6. Layshaft 15. 5th/reverse gear synchromesh
7. Output shaft 16. Selective spacers (output shaft and layshaft
8. Oil pump end float)
9. Oil filter 17. Selective spacer (5th gear/reverse hub)

DESCRIPTION AND OPERATION 1

MANUAL GEARBOX

2 DESCRIPTION AND OPERATION

 MANUAL GEARBOX

GEARBOX COMPONENTS - GEARS AND

SHAFTS

1. 3rd/4th gear selector fork 29. Output shaft taper bearing

2. Interlock spool 30. Selective shims
3. 1st/2nd gear selector fork 31. Selective washer
4. Selector shaft yoke pins 32. Bush
5. Selector shaft 33. Needle roller bearing
6. Reverse/5th gear selector fork 34. Reverse gear
7. Selector quadrant - Type A gearbox 35. Reverse gear synchromesh ring
8. Gear change lever yoke - Type B/D gearbox 36. Reverse/5th gear synchromesh hub and sleeve
9. Gear change lever yoke - Type C gearbox 37. Circlip
10. Input shaft front taper bearing 38. Needle roller bearings
11. Input shaft 39. 5th gear synchromesh ring
12. 4th gear synchromesh ring 40. 5th gear
13. Pilot taper bearing 41. 5th gear segments
14. Spacer 42. 5th gear segment retaining ring
15. 3rd/4th gear synchromesh hub and sleeve 43. Output shaft rear support bearing
16. 3rd gear synchromesh rings 44. Layshaft support bearing
17. 3rd gear 45. Layshaft
18. Needle roller bearings 46. Layshaft support bearing
19. Output shaft 47. Selective shims
20. Roll pin 48. Layshaft reverse gear
21. Needle bearing 49. Layshaft 5th gear
22. 2nd gear 50. Split washer - later gearboxes
23. 2nd gear synchromesh rings 51. 5th gear nut
24. 2nd/1st gear synchromesh hub and sleeve 52. Layshaft rear support bearing
25. 1st gear synchromesh rings 53. Spacer
26. 1st gear 54. Reverse idler gear
27. Needle roller bearing 55. Needle roller bearing
28. Bush 56. Reverse idler shaft

DESCRIPTION AND OPERATION 3

MANUAL GEARBOX

4 DESCRIPTION AND OPERATION

 MANUAL GEARBOX

GEARBOX CASINGS

1. Front cover - Early gearboxes 27. Oil filter

2. Front cover - Later gearboxes 28. Oil pick-up ring
3. Input shaft oil seal 29. Oil cooler adaptor
4. Oil filler/level plug 30. Bolt
5. Oil drain plug 31. ’O’ ring
6. Sealing washer 32. Extension housing - Type C gearbox
7. Gearcase 33. Gate plate and bolt - Type C gearbox
8. Interlock spool retainer, bolt and ’O’ ring - if 34. Inhibitor cam end plate and bolt - Type C
fitted gearbox
9. Centre plate 35. Interlock spool retainer, bolt and ’O’ ring - Type
10. Locating dowels C gearbox
11. Selector plug, detent balls and springs 36. Selector shaft oil seal - Type C gearbox
12. Splash shield and bolt 37. Spacer - Type C gearbox
13. Extension housing - Types A and B gearbox 38. Speedometer pinion - Type C gearbox
14. Gate plate and bolt 39. Oil seal - Type C gearbox
15. Interlock spool retainer, bolt and ’O’ ring 40. Output shaft drive flange - Type C gearbox
16. Inhibitor cam spring 41. ’O’ ring - Type C gearbox
17. Inhibitor cam 42. Spacer - Type C gearbox
18. Reverse inhibitor shaft 43. Tab washer - Type C gearbox
19. Output shaft oil seal collar 44. Drive flange bolt - Type C gearbox
20. Oil seal 45. Drive flange propeller shaft bolt - Type C
21. Oil pump gearbox
22. ’O’ ring 46. Support bracket - Type C gearbox
23. Reverse light switch 47. Extension housing - Type D gearbox
24. Oil cooler by-pass and bolt 48. Oil seal - Type D gearbox
25. ’O’ ring 49. Interlock spool retainer, bolt and ’O’ ring - Type
26. Oil pick-up pipe D gearbox

DESCRIPTION AND OPERATION 5

MANUAL GEARBOX

6 DESCRIPTION AND OPERATION

 MANUAL GEARBOX

GEAR CHANGE HOUSING - TYPE A GEARBOX

1. Gear change housing 13. ’O’ ring

2. Gasket 14. Trunnion
3. Roll pin 15. Circlip
4. Bias spring 16. Trunnion retaining screw
5. Gear lever retaining bolt and washer 17. Quadrant
6. Gear change housing bolts 18. Roll pin or setscrew
7. Gear lever 19. Rollers
8. Nylon pad and spring 20. Pin
9. Gear lever extension 21. Circlip
10. Remote housing 22. Ball pin seating
11. Blanking plug 23. 5th gear stop screw and locknut
12. Selector shaft

DESCRIPTION AND OPERATION 7

MANUAL GEARBOX

8 DESCRIPTION AND OPERATION

 MANUAL GEARBOX

GEAR CHANGE HOUSING - TYPE B GEARBOX

1. Gear change housing cover and gasket 6. Lower gear lever housing oil seal
2. Gear change housing 7. Bias springs
3. Bias adjustment plate and bolts 8. Bias spring retaining bolts
4. Lower gear lever 9. Upper gear lever and bolt
5. Railko bush

DESCRIPTION AND OPERATION 9

MANUAL GEARBOX

10 DESCRIPTION AND OPERATION

 MANUAL GEARBOX

REMOTE GEAR CHANGE HOUSING - TYPE C

GEARBOX

1. Remote gear change housing 10. Spacer

2. Selector rod yoke 11. Mounting rubbers
3. Pinch bolt 12. Flexible mounting
4. Bottom cover plate 13. Bias spring
5. Remote gear change bracket 14. Bridge plate liner
6. Ball pin 15. Bias spring bridge plate
7. Ball pin seating 16. Gear lever
8. Selector rod 17. Gear lever cap
9. Selector rod bush 18. Plunger
19. Anti-rattle spring

DESCRIPTION AND OPERATION 11

MANUAL GEARBOX

12 DESCRIPTION AND OPERATION

 MANUAL GEARBOX

TRANSFER BOX SELECTOR HOUSING - TYPE A

GEARBOX

1. Gaiter retaining bolt 10. Nylon seat

2. Gaiter 11. Cross shaft
3. Gaiter support plate 12. Gear lever
4. Gasket plate 13. Selector housing
5. Gaskets 14. Bushes
6. Spring clip 15. Countersunk screws
7. Clevis pin 16. End cover
8. Circlip retaining nylon seat 17. Selector fork
9. Gear lever ball 18. ’O’ rings

DESCRIPTION AND OPERATION 13

 MANUAL GEARBOX

GEARBOX DISMANTLE

Clutch housing - Type A gearbox - Remove

NOTE: Early type front cover illustrated.

2. Remove 2 bolts securing release lever pivot

NOTE: Early type front cover illustrated. post, remove post.
3. Remove 6 bolts securing clutch housing to
gearbox, remove housing.
1. If fitted: Remove and discard clips retaining
clutch release bearing pads, remove bearing NOTE: Dowel located.
and clutch release lever, recover pads.

OVERHAUL 1
MANUAL GEARBOX

Clutch housing - Type B gearbox - Remove Clutch housing - Type C gearbox - Remove

1. Pull clutch release lever off pivot post, remove

lever and clutch release bearing.

NOTE: Early type front cover illustrated.

1. Remove clutch release bearing.

2. Remove bolt 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.

NOTE: Early type front cover illustrated.

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.

2 OVERHAUL
 MANUAL GEARBOX

Clutch housing - Type D gearbox - Remove

NOTE: Early type front cover illustrated.

1. Remove 2 bolts securing release lever pivot

post; remove post.
NOTE: Type D gearboxes have a standard 2. Remove 6 bolts securing adaptor housing to
clutch housing adaptor which mates with gearbox; remove adaptor housing.
both V8 and diesel engine clutch
housings.The above illustration shows the
gearbox removed at the clutch housing adaptor
with the clutch housing adaptor (containing the
clutch mechanism) still fitted to the engine.

OVERHAUL 3
MANUAL GEARBOX

Gear change/selector housings - Type A gearbox Remote housing - Type A gearbox - Remove
- Remove

1. Noting their fitted position, remove 3 bolts

securing remote housing, remove housing.

NOTE: Dowel located.

1. Remove 4 bolts securing gear change housing,

remove housing.

NOTE: Dowel located.

2. Remove 4 bolts securing transfer box selector

housing, remove housing.

4 OVERHAUL
 MANUAL GEARBOX

Gear change/selector housings - Type B gearbox

- Remove

1. Remove 2 Torx screws securing gear change 2. Remove 4 bolts securing transfer box selector
housing cover, remove cover; recover sealing housing, remove housing.
rubber. 3. Noting their fitted position, remove 3 bolts
securing gear change housing, remove
housing.

NOTE: Dowel located.

OVERHAUL 5
MANUAL GEARBOX

Selector quadrant - Type A gearbox - Remove Gear change lever yoke - Type B gearbox -
Remove

1. Remove and discard set screw securing 1. Remove and discard set screw securing yoke.
selector quadrant. 2. Move selector shaft forwards, remove yoke.
2. Move selector shaft forwards, remove
quadrant.

6 OVERHAUL
 MANUAL GEARBOX

Remote gear change - Type C gearbox - Remove Remote gear change - Type D gearbox - Remove

1. Remove 4 bolts securing remote gear change

to extension housing; release remote gear
change from extension housing.

1. Noting fitted positions of mounting rubbers and

washers, remove 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.

OVERHAUL 7
MANUAL GEARBOX

Gear change lever yoke - Type D gearbox - Extension housing - Types A and B gearbox -
Remove Remove

1. Remove and discard set screw securing yoke.

2. Move selector shaft forwards, remove yoke.

1. Using LRT-37-009, LRT-37-010 and

LRT-37-001/2, remove output shaft oil seal
collar.

2. Remove bolt and washer securing interlock

spool retainer.
3. Remove interlock spool retainer, remove and
discard ’O’ ring.

8 OVERHAUL
 MANUAL GEARBOX

Extension housing - Type C gearbox - Remove

4. Noting fitted of 2 longest bolts, remove 10 bolts

securing the extension housing.
5. Place a suitable container underneath the
gearbox to catch any oil spillage and remove
the extension housing. 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 bolt and washer securing interlock
spool retainer.
4. Remove interlock spool retainer, remove and
discard ’O’ ring.
5. Noting fitted position of 2 longest bolts, remove
10 bolts securing extension housing to
gearcase.
6. Place a suitable container underneath the
gearbox to collect any oil spillage and remove
the extension housing.

NOTE: Speedometer drive gear may be a

tight fit on output shaft and this can
prevent removal of extension housing.
Insert suitable blocks of wood between
6. Remove oil filter. extension housing and centre plate and carefully
7. Secure centre plate to gearcase with 2 off 8 x lever extension housing away until drive gear is
35 mm slave bolts. released.

7. Remove and discard selector shaft oil seal.

OVERHAUL 9
MANUAL GEARBOX

Extension housing - Type D gearbox - Remove

8. Remove oil filter.

9. Secure centre plate to gearcase with 2 off 8 x
35 mm slave bolts.

1. Remove bolt and washer securing interlock

spool retainer.
2. Remove interlock spool retainer.
3. Remove and discard ’O’ ring - if fitted.

4. Noting fitted position of 2 longest bolts, remove

10 bolts securing extension housing to main
gearcase.
5. Using a soft faced mallet, tap extension
housing free from its location dowels.
6. Place a suitable container underneath the
gearbox to collect any oil spillage and remove
the extension housing.
7. Remove oil filter.
8. Secure centre plate to gearcase using 2 off 8 x
35 mm slave bolts.

10 OVERHAUL
 MANUAL GEARBOX

5th and Reverse gear - Remove

3. Remove staking from 5th laygear retaining nut,

fit tool LRT-37-023 to hold the 5th laygear.

NOTE: If 5th laygear is not drilled to

accept prongs of LRT-37-023, remove 13
1. Position gearcase as shown
mm (0.5 in) from each prong and locate
2. Using a suitable two legged puller remove 5th
prongs in counterbores machined in gear. The
gear layshaft support bearing track from the
modified tool may still be used on gearboxes
end of layshaft.
fitted with drilled gears.

4. Remove and discard the nut.

OVERHAUL 11
MANUAL GEARBOX

5. Remove thrust collar segments, retaining ring

and segments, drift out the roll pin.
6. Later gearboxes: Remove split washer
securing 5th laygear to shaft.
7. Remove 5th laygear.

12. Pull selector shaft out of gearcase until selector

spool can be rotated clear of fork. Remove 5th
and reverse synchromesh hub assembly
complete with fork and spool.
13. Remove output shaft reverse gear complete
8. Remove output shaft rear support bearing track with needle roller bearing and bush noting
using tools LRT-37-009, LRT-37-010 and selective spacer between reverse gear bush
LRT-37-001/2. and centre plate bearing.
9. Remove output shaft 5th gear with 14. Remove layshaft reverse gear.
synchromesh baulk ring.
10. Remove output shaft 5th gear split needle
roller bearing.
11. Remove and discard circlip securing 5th gear
synchromesh hub.

15. Remove centre plate Torx detent plug, spring

and ball.
16. Remove 2 bolts securing spool retainer,
remove retainer; remove and discard ’O’ ring -
if fitted.

12 OVERHAUL
 MANUAL GEARBOX

Output shaft and layshaft - Remove

1. Remove slave bolts securing centre plate.

4. Remove layshaft, output shaft and selector

2. Align selector shaft pin with slot in centre plate shaft from casing as an assembly.
and using wooden blocks and hide mallet, 5. Remove input shaft, and 4th gear baulk ring. (If
drive off centre plate; collect lower detent ball not already removed with output shaft).
and spring.

3. Remove bearing tracks and shims from centre

plate.

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MANUAL GEARBOX

Output shaft - Dismantle

1. Using LRT-99-002 and support bars under 1st

gear, press output shaft support bearing from
output shaft.
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.

14 OVERHAUL
 MANUAL GEARBOX

Gearcase

Degrease and clean all components. Inspect casing

for damage, cracks and stripped threads.

1. Fit oil filer/level plug.

CAUTION: Attach a suitable label

indicating gearbox oil is drained.

2. Fit new sealing washer to drain plug, fit plug

and tighten to 50 Nm (37 lbf.ft).

4. Invert output shaft and using LRT-99-002 and

support bars under 3rd gear, press off pilot
bearing.
5. Remove spacer, 3rd/4th gear synchromesh
selector hub, synchromesh baulk rings, 3rd
gear and needle bearing.

OVERHAUL 15
MANUAL GEARBOX

Front Cover - Remove Front Cover - Early Type - Dismantle

NOTE: Early type front cover can be

identified by the lug on each side of the
cover.

NOTE: Early type front cover illustrated.

1. Remove 6 bolts securing front cover to

gearcase, remove cover.
1. Remove input shaft bearing track from front
cover. Check that spring clips are intact.
2. Remove and discard oil seal from front cover.
3. Remove layshaft bearing track from front
cover.

16 OVERHAUL
 MANUAL GEARBOX

Front cover - Later Type - Dismantle Centre plate - Dismantle

NOTE: Later type front covers have one 1. Remove bearing tracks and shims.
lug only on the side of the cover and 2. Check selector rail bore for wear.
layshaft bearing track is pressed into the
cover.

1. Remove layshaft bearing track from front

3. Remove 2 bolts securing splash shield.
cover.
4. Press out reverse idler gear shaft using
2. Remove input shaft bearing track from front
suitable press and check shaft for wear.
cover, remove and discard oil seal .
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.

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MANUAL GEARBOX

Extension housings - Overhaul Type C gearbox - As for A and B Types and

including the following:
Types A and B gearbox
12. Recover speedometer drive gear and spacer.
1. Examine for damage to threads and machined 13. Check speedometer drive gear for wear and
faces. 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 interlock spool for wear, renew
interlock spool if necessary.

Type C and D gearboxes

CAUTION: The output shaft rear 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.

NOTE: Types A and B gearbox extension

housing shown.

2. Remove 3 screws and remove oil pump,

remove and discard ’O’ ring.
3. Remove oil pick-up pipe and check for
obstruction.
4. Drift out layshaft support bearing.
5. Remove and discard output shaft rear oil seal.
6. Drift out output shaft support bearing and oil
pick up ring.
7. Unscrew reverse inhibitor shaft.
8. Remove reverse inhibitor cam and spring.
9. Remove reverse light switch and sealing NOTE: Type D gearbox extension housing
washer, discard sealing washer. shown.
10. Remove gate plate.
11. Check all components for wear and renew as 1. Remove and discard output shaft oil seal.
necessary. 2. Remove 3 screws and remove oil pump,
remove and discard ’O’ ring.

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 MANUAL GEARBOX

Reassemble
Gear change/selector housings - Overhaul
1. Lubricate oil pump recess with gearbox oil.
2. Lubricate new ’O’ ring with gearbox oil and fit
to oil pump. Gear change housing - Type A gearbox
3. Locate oil pump into extension housing
ensuring that word ’TOP’ on pump is towards Dismantle
top of housing.
4. Align fixing screw holes and tap pump lightly at
edges until it is fully in housing, fit screws and
tighten to 6 Nm (4.5 lbf.ft).

CAUTION: Do not pull pump into housing

by tightening screws.

5. Fit new output shaft support bearing.

1. Using a suitable piece of tubing, release both

ends of bias spring from ball pins.
2. Slacken locknuts and remove bias spring
adjusting screws.
3. Drift out roll pin, remove bias spring.

6. Lubricate a new output shaft rear oil seal with

gearbox oil and fit seal using tool LRT-37-014.
7. Fit new layshaft support bearing.
8. Fit new oil pick-up ring ensuring that tag is
aligned with centre of drain slot.
9. Examine gate plate and renew if worn or
damaged.
10. Fit gate plate, fit bolts and tighten to 15 Nm (11
lbf.ft).
11. Fit reverse light switch and new sealing
washer. Tighten to 24 Nm (17 lbf.ft).
12. Apply Loctite 290 to threads of reverse inhibitor
shaft, position shaft and fit reverse inhibitor
cam and spring.
13. Tighten reverse inhibitor shaft.
14. Refit oil pick-up pipe, bend uppermost.

OVERHAUL 19
MANUAL GEARBOX

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 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

away from bias spring location.

3. Fit lower gear lever retaining bolt and special

washer, tighten bolt to 15 Nm (11 lbf.ft).
4. Fit extension to lower gear lever.
5. Position roll pin and bias spring to housing, fit
roll pin.
6. Fit bias spring adjusting screws and locknuts.
4. Remove extension from lower gear lever. 7. Using a suitable piece of tubing locate both
5. Remove bolt and special washer securing ends of bias spring over ball pins.
lower gear lever.
6. Carefully withdraw lower gear lever from NOTE: Do not adjust bias spring at this
housing ensuring that spring loaded nylon pad stage.
is retained during removal.

WARNING: Personal injury may result if

pad is not retained.

7. Release nylon pad, recover spring.

8. Clean all components.

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 MANUAL GEARBOX

Remote housing - Type A gearbox

Dismantle

4. Remove blanking plug from end of remote

housing.
5. Remove setscrew securing quadrant to
selector shaft, remove quadrant.
1. Remove setscrew securing trunnion to selector
shaft, remove trunnion. NOTE: Early gearboxes: Quadrant is
2. Remove and discard circlip securing ball pin secured by a roll pin.
seating to trunnion, remove seating.
3. Loosen locknut, remove 5th gear stop screw. 6. Remove selector shaft from remote housing,
remove and discard ’O’ ring.
7. Remove and discard circlip retaining rollers
and pin to quadrant.
8. Remove pin, recover rollers.
9. Clean all components.

Inspection

1. Check selector shaft and bore in remote

housing for wear.
2. Check quadrant rollers and pin for wear.
3. Check ball pin seating for wear.
4. Replace worn components as necessary.

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MANUAL GEARBOX

Reassemble Gear change housing - Type B gearbox

1. Lubricate selector shaft and new ’O’ ring with Dismantle

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 290 to threads of setscrew, fit
setscrew and tighten to 25 Nm (18 lbf.ft).

NOTE: Early gearboxes: Fit new roll pin.

7. Apply Loctite 290 to threads of blanking plug,

fit plug and tighten to 30 Nm (22 lbf.ft).
8. Smear ball pin seating with multi-purpose
grease.
9. Position ball pin seating in trunnion, secure 1. Remove bolts retaining bias springs.
with a new circlip.
10. Position trunnion on selector shaft. WARNING: To avoid personal injury,
11. Apply Loctite 290 to threads of setscrew, fit restrain each spring in turn with a pair of
setscrew and tighten to 25 Nm (18 lbf.ft). grips while the bolts are being removed.
12. Fit 5th gear stop screw, fit but do not tighten
locknut. 2. Remove the two bias springs.
3. Remove 2 bolts securing bias spring
NOTE: 5th gear stop screw adjustment is adjustment plate.
carried out during gearbox reassembly.

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 MANUAL GEARBOX

Inspection

1. Check ball cross pin slots in gear change

housing for wear.
2. Check ball and pins for wear.
3. Check bias springs for distortion.
4. Replace worn components as necessary.

Reassemble

1. Apply multi-purpose grease to ball and cross

pins.
2. Apply multi-purpose grease to new Railko bush
and fit to gear change housing.

CAUTION: Ensure that the slots in each

bush are aligned with slots in housing.

3. Lubricate a new oil seal with gearbox oil.

4. Lift lower lever assembly out of gear change 4. Fit oil seal, lip side towards housing, using a
housing. suitable mandrel.
5. Remove and discard Railko bush. 5. Position gear lever to gear change housing
6. Remove and discard oil seal from housing. ensuring ball cross pins are located in slots in
7. Clean all components. housing and Railko bush.
6. Position bias spring adjustment plate to gear
change housing,
7. Apply Loctite 290 to threads of 2 short bias
spring adjustment plate bolts.
8. Fit bolts to secure front of bias adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9. Position bias spring to pillar ensuring longest
end of spring is against gear lever.
10. Apply Loctite 290 to threads of 2 long bias
adjustment plate bolts.
11. Restrain bias spring using a suitable pair of
grips, ensure short end of bias spring is
positioned on outside edge of bolt hole.

WARNING: Personal injury may result if

bias spring is not retained.

12. Fit bolt and washer ensuring end of bias spring

is restrained beneath washer; tighten bolt to 25
Nm (18 lbf.ft).
13. Repeat above procedures for remaining bias
spring.

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MANUAL GEARBOX

Remote gear change - Type C gearbox Inspection

Dismantle 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, bushes
and 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
1. Remove 2 bolts and 2 countersunk screws as a set if necessary.
securing bias spring bridge plates.
2. Remove bridge plates, bridge plate liners and Reassemble
bias spring.
3. Remove 4 bolts and washers securing bottom 1. Lubricate selector rod and bushes with multi -
cover plate, remove plate. purpose grease, insert rod in remote housing.
4. Remove bolt securing gear lever cap, remove 2. Lubricate gear lever ball pin and selector rod
cap. yoke balls with multi-purpose grease.
5. Remove gear lever, recover anti-rattle spring 3. Fit yoke to selector rod, fit pinch bolt and
and plunger. tighten to 25 Nm (18 lbf.ft).
6. Remove pinch bolt securing selector rod yoke, 4. Assemble anti-rattle spring and plunger to gear
remove yoke. lever.
7. Withdraw selector rod from remote housing. 5. Fit gear lever ensuring ball pin is located in
8. Clean all components. yoke and anti-rattle spring and plunger are not
displaced.
6. Fit gear lever cap, fit bolt and tighten to 15 Nm
(11 lbf.ft).

NOTE: Do not fit bottom cover plate at this

stage.

7. Loosen bias spring adjustment bolt locknuts.

8. Fit bias spring, bridge plate liners and bridge
plates.
9. Fit bolts and countersunk screws and tighten to
25 Nm (18 lbf.ft).

NOTE: Final adjustment of bias spring is

carried out after remote gear change is
fitted to gearbox.

24 OVERHAUL
 MANUAL GEARBOX

Remote gear change - Type D gearbox Transfer box selector housing - Type A gearbox -
Overhaul

Dismantle

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.

NOTE: With the exception of the reverse

light switch, the remote gear change fitted
to Type D gearboxes is not a repairable
item. It must be replaced if components are
found to be worn.

4. Remove and discard spring clip retaining

selector fork clevis pin.
5. Remove clevis pin from selector fork, remove
and discard 2 bushes.

OVERHAUL 25
MANUAL GEARBOX

Inspection

1. Check gaiter for splits and damage.

2. Check nylon seating and ball for wear, replace
if necessary.

CAUTION: Seating and ball should be

renewed as an assembly.

3. Check selector fork and clevis pin for wear.

4. Check cross shaft and end cover for wear.
5. Replace components as necessary.

Reassemble

1. Lubricate new ’O’ rings with gearbox oil and fit

to selector fork, position fork in housing.
2. Lubricate cross shaft with multi-purpose grease
and locate longest end of shaft in selector fork.
3. Lubricate new ’O’ rings with gearbox oil and fit
to end cover.
4. Position end cover on cross shaft, fit and
6. Remove and discard circlip retaining nylon ball tighten countersunk screws.
seating. 5. Assemble ball and nylon seating to gear lever
7. Remove gear lever, recover nylon seating and ensuring that groove in seating is towards
ball. cross shaft.
6. Lubricate ball and nylon seating with multi -
purpose grease and locate in cross shaft;
retain with a new circlip.
7. Position new bushes to gear lever, locate in
selector fork and fit clevis pin.
8. Fit new spring clip to retain clevis pin.
9. Position gate plate and gaiter support plate to
housing, use new gaskets.
10. Fit retaining bolts and tighten to 15 Nm (11
lbf.ft).
11. Fit gaiter.

8. Remove 2 countersunk head screws securing

end cover to housing.
9. Remove end cover, remove and discard 2 ’O’
rings.
10. Withdraw cross shaft.
11. Remove selector fork, remove and discard 2
’O’ rings.
12. Clean all components.

26 OVERHAUL
 MANUAL GEARBOX

Synchromesh assemblies - Overhaul

6. Examine the dog teeth 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.

Reassemble

8. Refit inner hub to sleeve.

NOTE: Hubs and sleeves have a master

spline combination and can only be
1. Remove spring clips from both sides of assembled one way. The sleeves are
assembly. further identified with a series of half moon
2. Remove slippers and separate the hub from notches which clearly identify which side of the
the sleeve. assembly faces which gear. Ensure the slot in
3. Examine all parts for damage and wear, check the hub aligns with the centre notch on the
spring clips for tension. sleeve.
4. Check no excessive radial movement exists
between inner members and output shaft Assy Hub Sleeve Against
splines. Gear
5. Examine inner and outer splines for wear.
1st/2nd - 1 Notch 1st
2 gear - 2nd
side
3rd/4th - 3 Notches 3rd
- - 4th
5th/Rev - 5 Notches 5th

9. Fit slippers and secure with a spring each side

of the synchromesh assembly ensuring the
step on each spring locates on a different
slipper.

NOTE: 5th and reverse synchromesh hubs

have different springs which are coloured
yellow.

OVERHAUL 27
MANUAL GEARBOX

Checking baulk ring clearances Input shaft - Overhaul

1. Examine the gear and dog teeth for wear and

damage.

2. Using LRT-99-004 and LRT-37-004 remove

pilot bearing track.
Check clearance of all baulk rings and gears by
pressing the baulk rings against the gear and CAUTION: Ensure that the bearing is
measuring the gap. supported by the lip inside LRT-37-004.
Minimum clearance - 0.5 mm (0.020 in).

3. Using LRT-37-043 and LRT-99-002 remove

taper roller bearing.

28 OVERHAUL
 MANUAL GEARBOX

Output shaft - Inspection

1. 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
4. Using LRT-99-002, LRT-37-043 and from pump and feed to spigot bearing are
LRT-37-043/2, fit a new taper roller bearing. clear.
4. Check oil feed holes to roller bearing are clear.

5. Support the shaft under LRT-99-002 and using

a suitable mandrel, fit a new taper roller
bearing.

OVERHAUL 29
MANUAL GEARBOX

Layshaft - Overhaul

1. Using LRT-99-002, LRT-37-022 and

LRT-37-044, remove 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.

3. Using press LRT-99-002 and a suitable

mandrel, positioned on bearing inner race, fit
new taper roller bearings.

30 OVERHAUL
 MANUAL GEARBOX

Output shaft - Reassemble

1. Clamp output shaft in protected vice jaws, 6. Check 1st and 2nd gear end-float.
output end upwards.
2. Fit 2nd gear needle roller bearing, 2nd gear
and synchromesh baulk rings on to output
shaft.

NOTE: Rotate each baulk ring to ensure

they locate onto each other.

3. Assemble the 1st and 2nd synchromesh

selector hub on to output shaft splines, noting
the 2nd gear side marking. Ensure that baulk
ring has located correctly inside hub.

NOTE: Rotate the ring slightly as the hub

is lowered.
Checking 1st gear end-float
4. Fit 1st gear synchromesh baulk rings, needle
roller bearing, 1st gear and bush on to output New: 0.05 - 0.20 mm (0.002 - 0.008 in)
shaft ensuring baulk rings locate correctly Service limit: 0.327 mm (0.012 in)
inside selector hub.
5. Using LRT-99-002, and a suitable mandrel
positioned on bearing inner race, press on
output shaft taper roller bearing taking care not
to disturb the position of the synchromesh
baulk rings and gears.

OVERHAUL 31
MANUAL GEARBOX

Check end float of 3rd gear.

Checking 2nd gear end-float

New: 0.04 - 0.21 mm (0.0016 - 0.008 in) Checking 3rd gear end-float
Service limit: 0.337 mm (0.013 in)
New: 0.11 - 0.21 mm (0.004 - 0.008 in)
7. Invert output shaft in vice and fit 3rd gear Service limit: 0.337 mm (0.013 in)
needle roller bearing, third gear and
synchromesh baulk rings.
8. Assemble 3rd/4th gear synchromesh selector
hub, noting 3rd speed side markings, on to
output shaft splines taking care to locate the
baulk rings into recesses in the selector hub.
9. Fit spacer.

10. Using LRT-99-002 and a suitable mandrel

positioned on bearing inner race, press on new
pilot bearing.

32 OVERHAUL
 MANUAL GEARBOX

Reverse idler gear and centre plate - Reassemble Selectors - Inspection

1. Examine components for wear and damage.

2. Assemble reverse idler gear needle roller

bearing, idler gear, spacer and shaft and using
suitable tool, press into centre plate.
1. Examine selector rail and pins for wear and
3. Using feeler gauges, check clearance between
damage.
reverse idler gear and shaft flange, fit a thicker
2. Examine selector forks for wear and damage.
or thinner spacer if necessary in order to
achieve correct clearance.
NOTE: The selector rail and fork is only
New clearance:
supplied as a complete assembly.
0.04 - 0.38 mm (0.0016in - 0.015 in)
Service limit:
3. Examine interlock spools for wear and
0.38 mm (0.015 in)
damage.
4. Fit splash shield, fit bolts and tighten to 8 Nm
(6 lbf.ft).

CAUTION: Do not fit detent balls or

springs at this stage.

OVERHAUL 33
MANUAL GEARBOX

GEARBOX REASSEMBLE
Selectors - Reassemble

Output shaft and layshaft end float

NOTE: The end float setting for both the

output shaft and the layshaft has to be
determined before the gearbox can be
reassembled. This is achieved by clamping the
output shaft and layshaft separately between the
centre plate and main casing and measuring the
movement of each shaft with a dial test indicator.

1. Rest 1st/2nd fork and shaft assembly on bench Shimming

and locate pin in jaw of fork.
2. Fit interlock spool and 3rd/4th fork and engage 1. Fit new bearing tracks to front cover.
spool in jaw of fork.
CAUTION: Ensure input shaft bearing
track is correct for type of front cover
fitted. Early covers having a lug each side
of cover, bearing track is retained with a spring
clip. Later covers having a lug on one side of
cover, press bearing track into cover using a
suitable mandrel.

2. Fit front cover to gearcase without oil seal.

3. Clamp gearcase in vice with front cover
downwards.
4. Fit input shaft.
3. Slide spool and fork towards 1st/2nd selector
until slot in spool locates over pin keeping the CAUTION: Do not fit 4th gear baulk ring.
spool engaged in 3rd/4th fork jaw.

5. Fit output shaft assembly to input shaft.

6. Fit output shaft bearing shim and track to
centre plate.

34 OVERHAUL
 MANUAL GEARBOX

Assembling output shaft and layshaft to centre

plate

1. Secure centre plate to suitable workstand.

2. Fit selected shims and bearing tracks.
3. Fit lower detent ball and spring, use a dummy
bar to temporarily hold the ball in place.

7. Fit centre plate and bolt down using 8 off 8 x

35 mm slave bolts.

CAUTION: Do not fit detent ball or spring

at this stage.

8. Fit large ball bearing to rear of output shaft.

9. Mount dial test indicator.
10. Rotate output shaft to settle bearings.
11. Lift output shaft and note DTI reading.

The end float setting for the output shaft and

layshaft is:-
Early gearboxes without suffix K added to serial
number:
New: 0.01 - 0.06 mm (0.0004 - 0.0024 in)
4. Check both synchromesh units are in neutral
Service limit: 0.06 mm (0.0024 in)
and fit selector shaft assembly to output shaft.
5. Fit output shaft and selectors as complete unit
Later gearboxes with suffix K added to serial
to centre plate aligning pin with slot in plate.
number:
New: 0.00 - 0.05 mm (0.00 - 0.002 in)
CAUTION: Take care that as dummy shaft
Service limit: 0.05 mm (0.002 in)
is removed, detent spring and ball are not
displaced.
Shims to make up the required clearances are
placed under the respective bearing tracks in the
6. Fit 4th gear synchromesh baulk ring.
centre plate.

12. Dismantle and substitute shims if reading

incorrect.
13. Remove output shaft assembly and repeat
procedure for layshaft.
14. Remove centre plate, layshaft and output shaft.
15. Remove front cover.
16. Remove input shaft bearing track from front
cover, retain track with cover.

OVERHAUL 35
MANUAL GEARBOX

NOTE: Early type front cover illustrated.

9. Fit new oil seal to front cover. Ensure seal is

fitted down to shoulder. Apply sealant, Part No.
STC 3254 to front cover as shown.

CAUTION: Oil seal must be fitted dry.

10. Fit input and layshaft bearing tracks in front

cover.
11. Apply Loctite 290 to threads of front cover
bolts, fit bolts and tighten by diagonal selection
to 25 Nm (18 lbf.ft).
7. Fit layshaft whilst lifting output shaft to clear 12. Apply sealant, Part No. STC 3254 to centre
layshaft rear bearing. plate and fit main casing to centre plate.
8. Lubricate pilot bearing with gearbox oil and fit 13. Bolt casing and centre plate together using 2
input shaft. off 8 x 35 slave bolts.
14. Lubricate a new ’O’ ring with gearbox oil and fit
to interlock spool retainer.
15. Fit interlock spool retainer, fit bolt and tighten
to 8 Nm (6 lbf.ft).
16. Remove casing from stand and clamp in vice.

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 MANUAL GEARBOX

Reverse and 5th gear - Reassemble

1. Fit output shaft reverse gear selective washer, 6. Fit 5th gear split needle bearing.
bush and needle bearing. 7. Fit 5th gear and 5th gear synchromesh baulk
2. Fit output shaft reverse gear and synchromesh ring to output shaft, fit layshaft 5th gear.
baulk ring. 8. Later gearboxes: Fit split washer to retain
3. Fit layshaft reverse gear. layshaft 5th gear.
4. Assemble selector spool, selector fork and
reverse/5th gear synchromesh hub. Fit as one NOTE: Bevelled side of washer must face
assembly to output shaft splines and selector towards gear.
shaft.

CAUTION: Ensure synchromesh baulk 9. Fit new output shaft thrust collar roll pin. Locate
ring locates inside hub. 5th gear thrust segments and retaining ring.

5. Fit new circlip.

NOTE: The fit of the circlip is controlled by

the selective washer behind the reverse
gear. Adjust to 0.005 - 0.055 mm (0.0002 -
0.002 in).

OVERHAUL 37
MANUAL GEARBOX

10. Using LRT-37-023 to hold layshaft 5th gear, fit

a new layshaft stake nut and tighten to 220 Nm
(162 lbf.ft).
11. Stake layshaft 5th gear nut.
14. Fit centre plate detent ball and spring.
15. Apply Loctite 290 to threads of detent plug, fit
plug and tighten to 25 Nm (18 lbf.ft).
16. Move selector shaft and check that detent balls
can be felt to engage in detent.

12. Using LRT-37-015 and LRT-37-021 press

output shaft rear support bearing track to collar
on output shaft.
13. Apply small amount of heat and fit layshaft rear
support bearing.

38 OVERHAUL
 MANUAL GEARBOX

Extension housing - Type A and B Gearbox -

Refit

1. Remove slave bolts from centre plate.

5. Lubricate a new ’O’ ring with gearbox oil and fit

to extension housing interlock spool retainer.
Fit retainer, fit bolt and washer and tighten bolt
to 8 Nm (6 lbf.ft).

2. Fit oil filter.

3. Apply sealant, Part No. STC 3254 to mating
surfaces and fit extension housing ensuring oil
pipe locates in filter and drive locates in oil
pump.

CAUTION: Do not use force, if necessary,

remove extension housing and re - align
oil pump drive.

4. Apply Loctite 290 to threads of extension

housing securing bolts, fit bolts and tighten by
diagonal selection to 25 Nm (18 lbf.ft).

6. Using LRT-37-015 and LRT-37-021 press on

output shaft oil seal collar, narrow portion of
collar leading.

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MANUAL GEARBOX

Extension housing - Type C gearbox - Refit Extension housing - Type D gearbox - Refit

1. Lubricate a new selector shaft oil seal with

gearbox oil and fit seal.
2. Remove slave bolts from centre plate.
3. Fit oil filter.
4. Fit spacer
5. Position speedometer drive gear on output
shaft splines.
6. Using a round nosed punch, carefully tap
speedometer drive gear into position.
7. Apply sealant, Part No. STC 3254 to mating
surfaces.
8. Fit extension housing ensuring oil pipe locates
in filter and drive locates in oil pump.

CAUTION: Do not use force, if necessary,

remove extension housing and re-align oil
pump drive. 1. Remove slave bolts from centre plate.
2. Fit oil filter.
9. Apply Loctite 290 to threads of extension 3. Apply sealant, Part No. STC 3254 to mating
housing bolts, fit bolts and tighten by diagonal surfaces and fit extension housing. Ensure that
selection to 25 Nm (18 lbf.ft). oil pipe locates in filter and that drive locates in
10. Lubricate a new ’O’ ring with gearbox oil and fit oil pump.
to speedometer pinion housing.
11. Lubricate speedometer pinion with silicone CAUTION: Do not use force. If necessary,
grease. remove extension housing and re-align oil
12. Fit speedometer pinion housing ensuring teeth pump drive.
of pinion mesh with those of driven gear.
13. Lubricate a new ’O’ ring with gearbox oil and fit 4. Apply Loctite 290 to threads of extension
to extension housing interlock spool retainer. housing retaining bolts, fit bolts and tighten by
Fit retainer, fit bolt and washer and tighten bolt diagonal selection to 25 Nm (18 lbf.ft).
to 8 Nm (6 lbf.ft).
14. Fit selector shaft pin to selector shaft, fit and
tighten a new self-locking nut.

5. Lubricate a new ’O’ ring with gearbox oil and fit

to interlock spool retainer. Fit retainer, fit bolt
and washer and tighten bolt to 8 Nm (6 lbf.ft).

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 MANUAL GEARBOX

Selector quadrant - Type A gearbox - Refit Gear change lever yoke - Type B gearbox - Refit

1. Position selector quadrant to selector shaft. 1. Position gear change lever yoke on selector
2. Apply Loctite 290 to threads of a new setscrew. shaft with ball facing towards output shaft.
Fit and tighten screw to 25 Nm (18 lbf.ft). 2. Apply Loctite 290 to threads of a new setscrew,
fit and tighten screw to 25 Nm (18 lbf.ft).
CAUTION: Ensure end of setscrew locates
in hole in selector shaft. CAUTION: Ensure end of setscrew locates
in hole in selector shaft.

3. Move selector shaft to neutral position.

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MANUAL GEARBOX

Gear change lever yoke - Type D gearbox - Refit Remote housing - Type A gearbox - Refit

1. Apply sealant, Part No. STC 3254 to mating

surfaces and fit to extension housing.
2. Position remote housing to extension housing
and gearcase ensuring rollers locate in
quadrant.

1. Position gear lever yoke on selector shaft with

ball facing towards output shaft.
2. Apply Loctite 290 to threads of a new setscrew.
Fit and tighten screw to 25 Nm (18 lbf.ft).
3. Fit and lightly tighten 3 bolts in positions
CAUTION: Ensure end of setscrew locates shown.
in hole in selector shaft.
NOTE: Bolts are tightened when gear
change housing is fitted.

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 MANUAL GEARBOX

Transfer box selector housing - Type A gearbox - Gear change housing - Type A gearbox - Refit
Refit
1. Smear a new gasket with grease and fit to
1. Smear a new gasket with grease and fit to remote housing.
remote housing. 2. Position gear change housing to remote
2. Position transfer box selector housing to housing ensuring gear lever ball is correctly
remote housing. located.
3. Fit and lightly tighten 4 bolts. 3. Fit and lightly tighten 4 bolts.
4. Tighten remote housing, transfer box selector
NOTE: Bolts are tightened when gear housing and gear change housing bolts to 25
change housing is fitted. Nm (18 lbf.ft).
5. Adjust 5th gear stop screw.

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MANUAL GEARBOX

5th gear stop screw adjustment - Type A Transfer box selector housing - Type B gearbox -
gearbox Refit

1. Select reverse gear. While applying light 1. Smear a new gasket with grease and fit to
pressure to gear lever towards left, turn screw gearcase.
clockwise until it contacts yoke. 2. Position transfer box selector housing to
2. Turn screw anti-clockwise until 25 mm (1.0 in) gearcase, fit 4 bolts and tighten to 25 Nm (18
of free play is felt at knob, ensure 5th gear can lbf.ft).
be engaged.
3. Tighten locknut.
4. Check all other gears can be selected.

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 MANUAL GEARBOX

Gear change housing - Type B gearbox - Refit Remote gear change - Type C gearbox - Refit

1. Apply lithium based grease to selector rod

yoke.
2. Position remote gear change to extension
housing ensuring selector shaft pin is located
in selector rod yoke.
3. Fit bolts, washers and mounting rubbers
securing remote gear change to extension
housing; do not tighten bolts at this stage.
4. Fit bolts, washers and mounting rubbers
securing bracket to extension housing.
5. Tighten all bolts to 25 Nm (18 lbf.ft).

1. Apply sealant, Part No. STC 3254 to mating

surfaces of extension housing.
2. Position gear change housing to extension
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 (18 lbf.ft).

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MANUAL GEARBOX

Remote gear change - Type D gearbox - Refit Bias spring adjustment - Type A 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.

1. Apply sealant, Part No. STC 3254 to mating

surfaces of extension housing and remote gear
change housing.
2. Position remote gear change housing on
extension housing. Ensure that gear lever ball
is correctly located.
3. Fit bolts and tighten to 25 Nm (18 lbf.ft).
1. Select third or fourth gear.
2. Adjust the two adjusting screws until both legs
of the spring are approximately 0.5 mm (0.02
in) 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 gate several times. The gear lever
should return to the third and fourth gate.

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 MANUAL GEARBOX

Bias spring adjustment - Type B gearbox 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.

1. Loosen bias adjustment plate bolts. Select

fourth gear and move lever fully to the right.
2. Tighten bias adjustment plate bolts to 25 Nm
(18 lbf.ft).
3. Check adjustment is correct by selecting third
and fourth gears. 1. Adjust both bias spring adjustment bolts until a
clearance of 0.5 mm (0.02 in) 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.

4. Fit sealing rubber to gear change housing, fit

housing.
5. Apply Loctite 290 to threads of securing
screws, fit screws and tighten to 8 Nm (6 lbf.ft)

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MANUAL GEARBOX

Clutch housing - Type A gearbox - Refit Clutch housing - Type B gearbox - Refit

1. Position clutch housing to gearbox.

2. Fit securing bolts.

NOTE: The 12 x 45 mm bolts must be fitted

through locating dowels.

3. Tighten bolts by diagonal selection to 72 Nm

(53 lbf.ft).
4. Fit pivot post, fit and tighten bolts.
5. Apply lithium based grease to pivot post, pads
and push rod.
6. Position pads to clutch release lever, fit release 1. Position clutch housing to gearbox.
bearing. 2. Fit securing bolts.
7. Fit new clips to retain pads.
NOTE: The 12 x 45 mm bolts must be fitted
NOTE: Clips may become displaced in through locating dowels.
service with no loss of performance.
3. Tighten bolts by diagonal selection to 72 Nm
8. Fit release lever. (53 lbf.ft).
9. Apply lithium based grease to splines of input 4. Apply lithium based grease to pivot post,
shaft. release lever, socket and push rod.
5. Fit a new ’C’ clip to pivot post, fit post.
6. Fit spring clip to release lever, fit but do not
tighten bolt.

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 MANUAL GEARBOX

7. Position release lever to pivot post ensuring Clutch housing - Type C gearbox - Refit
spring clip is located behind ’C’ clip; tighten
bolt. 1. Position clutch housing to gearbox.
8. Fit clutch release bearing and retain using new 2. Fit securing bolts.
clips.
NOTE: The 2 longest bolts must be fitted
NOTE: Clips may become displaced in at locating dowel positions.
service with no loss of performance.
3. Tighten bolts by diagonal selection to 72 Nm
9. Apply lithium based grease to splines of input (53 lbf.ft).
shaft. 4. Apply lithium based grease to pivot post.
5. Fit release lever and clutch release bearing.
6. Apply lithium based grease to splines of input
shaft.

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MANUAL GEARBOX

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 locating dowel positions.

3. Tighten bolts by diagonal selection to 72 Nm

(53 lbf.ft).
4. Apply lithium based grease to pivot post.
5. Fit pivot post, fit 2 bolts and tighten to 25 Nm
(18 lbf.ft).
6. Apply lithium based grease to splines of input
shaft.

50 OVERHAUL