Page 490 of 1529
MANUAL GEARBOX - R380
REPAIRS 37-19
32.Remove 8 bolts securing gearbox to engine.
33.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.With assistance raise gearbox on jack and
align to clutch and engine.
3.Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4.Clean oil cooling pipe housing mating faces.
5.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6.Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8.Position breather pipes and secure 'P' clip with
bolt.
9.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12.Secure cable to fuel pipes with new cable ties.
13.Raise gearbox, ensuring gear change lever is
located in grommet.
14.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15.Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16.Remove 3 bolts securing support plate to
gearbox. 17.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18.Clean handbrake back plate and mating face.
19.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20.Clean handbrake drum.
21.Fit handbrake drum and tighten retaining
screw.
22.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front..
23.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
24.Clean exhaust silencer and tail pipe mating
faces.
25.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
27.Refit starter motor.
+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
28.Refill gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Manual gearbox.
29.Refill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31.Fit gear lever trim and gear change knob.
32.Connect battery earth lead.
33.Fit cooling fan cowl and battery cover and
secure fixings.
Page 492 of 1529
MANUAL GEARBOX - R380
REPAIRS 37-21
Seal - input shaft
$% 37.23.06
Remove
1.Remove gearbox assembly.
+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
4.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 5.Remove 6 bolts securing bell housing and
remove bell housing.
6.Remove and discard 6 bolts securing oil seal
housing and remove housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing.
Page 493 of 1529
MANUAL GEARBOX - R380
37-22 REPAIRS
Refit
1.Using a suitable solvent clean seal housing
mating faces.
2.Clean seal recess, bearings and bearing races.
3.Lubricate new oil seal and fit using a suitable
mandrel into housing.
4.Fit input shaft front bearing track using a press
and suitable mandrel.
5.Apply sealant, Part No. STC 4404 to seal
housing.
6.Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7.Clean bell housing mating faces, dowels and
dowel holes.
8.Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9.Clean release bearing sleeve mating faces,
dowel and dowel holes.
10.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11.Examine clutch release fork pivot points for
wear and replace as required.
12.Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13.Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14.Clean release bearing and bearing sleeve
mating faces.
15.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16.Fit release bearing and secure with retaining
peg.
17.Fit gearbox assembly.
+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Page 523 of 1529
MANUAL GEARBOX - R380
37-52 OVERHAUL
Reassembly
1.Clean components.
2.Apply multi-purpose grease to ball and cross
pins.
3.Apply multi-purpose to new Railko bush and fit
to housing ensuring that slots are correctly
aligned.
4.Lubricate a new seal with gearbox oil and fit, lip
side towards housing using a suitable mandrel.
5.Position lower gear lever to selector housing
ensuring cross pins are located in Railko bush.
6.Position bias spring adjustment plate to
selector housing.
7.Clean threads of bias spring adjustment plate
bolts and apply sealant, Part No. STC 50552 to
threads.
8.Fit 2 short bolts to secure front of adjustment
plate and tighten to 25 Nm (18 lbf.ft).
9.Position right hand bias spring to pillar ensuring
longest end of spring is against gear lever.
10.Restrain bias spring using a suitable pair of
grips, ensure shortest end of spring is on
outside edge of bolt hole.
11.Fit longest bolt and washer ensuring end of
bias spring is under washer, tighten bolt to 25
Nm (18 lbf.ft).
12.Repeat above procedures for remaining bias
spring.
13.Fit gear selector housing.
+ MANUAL GEARBOX - R380,
OVERHAUL, Housing - gear selector
mechanism.
14.Adjust gear lever bias springs.
+ MANUAL GEARBOX - R380,
ADJUSTMENTS, Spring - gear lever bias.
Housing - clutch
$% 37.12.07
Disassembly
1.Remove clutch release bearing and operating
lever.
2.Remove 6 bolts and remove clutch housing.
Reassembly
1.Clean clutch housing and gearbox mating face.
2.Position clutch housing and tighten bolts to 75
Nm (55 lbf.ft).
3.Fit clutch operating lever and release bearing.
Page 524 of 1529
MANUAL GEARBOX - R380
OVERHAUL 37-53
Cover - front
$% 37.12.33.01
Disassembly
1.Remove retaining peg and remove release
bearing.
2.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch
release fork.
3.Remove 2 bolts securing release bearing
sleeve and remove bearing sleeve. 4.Remove 6 bolts securing clutch housing and
remove clutch housing.
5.Remove and discard 6 bolts securing oil seal
housing.
6.Remove oil seal housing.
7.Using a soft metal drift, carefully remove input
shaft front bearing track from housing.
8.Remove oil seal from housing, discard seal.
Page 525 of 1529
MANUAL GEARBOX - R380
37-54 OVERHAUL
Reassembly
1.Using a suitable solvent cleaner, clean seal
housing mating faces.
2.Clean seal recess, bearings and bearing
races.
3.Lubricate new oil seal and fit using a suitable
mandrel into housing.
4.Fit input shaft front bearing track using a press
and suitable mandrel.
5.Apply sealant, Part No. STC 4404 to seal
housing, fit new bolts and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
6.Clean clutch housing mating faces, dowels and
dowel holes.
7.Position clutch housing, fit bolts and tighten to
75 Nm (55 lbf.ft).
8.Clean release bearing sleeve mating faces,
dowel and dowel holes.
9.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
10.Examine clutch release fork pivot points for
wear and replace as required.
11.Apply a smear of Molybdenum disulphide
grease to pivot points and position release fork.
12.Fit retaining clip ensuring it locates over pivot
point washer, fit bolt to release fork and tighten
to 10 Nm (7 lbf.ft).
13.Clean release bearing and bearing sleeve
mating faces.
14.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
15.Fit release bearing and secure with retaining
peg.
Page 528 of 1529
TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-3
1Rear output housing
2Differential rear bearing
3High range gear and bush
4Main casing
5High/low selector sleeve and hub
6Low range gear
7Differential assembly
8Front output housing
9Differential front bearing
10Selective shim - differential bearing pre-load
11Dog clutch - Differential lock
12Front output flange13Differential lock selector shaft - Differential lock
14Selector fork - Differential lock
15Front output shaft
16Selective spacer - intermediate gear bearing
pre-load
17Mainshaft input gear
18Selective shim - input gear bearing pre-load
19Intermediate shaft
20Intermediate gear cluster
21Rear output shaft
22Rear output flange
Page 534 of 1529
TRANSFER BOX - LT230SE
DESCRIPTION AND OPERATION 41-9
1Breather pipe, banjo bolt and sealing washers
2Bolt - high/low cross shaft housing and
abutment bracket
3Selector cable abutment bracket
4Multiplug bracket
5Hollow plug
6High/low cross shaft housing
7'O' ring
8High/low cross shaft and lever
9Front output shaft - Differential lock - If fitted
10Dog clutch - Differential lock - If fitted
11Warning lamp switch - Differential lock - If fitted
12Detent plug - Differential lock - If fitted
13Detent spring - Differential lock - If fitted
14Selector shaft - Differential lock - If fitted
15Detent ball - Differential lock - If fitted
16Threaded spacer - Differential lock - If fitted
17Front output housing
18Spring and clips - Differential lock - If fitted
19Bolt - cover plate
20Cover plate
21Selector fork - Differential lock - If fitted22Bolt - front output housing
23Hollow plug
24Circlip
25Front output flange
26Steel washer
27Self-locking nut
28Felt washer
29Oil seal
30Output shaft bearing
31Bearing spacer
32High/low detect switch
33Selector finger and shaft - Differential lock - If
fitted
34'O' rings - Differential lock - If fitted
35Bolt - selector housing - Differential lock - If
fitted
36Selector housing - Differential lock - If fitted
37High/low selector finger
38Front output shaft - Vehicles not fitted with
differential lock
