R380 Rebuild

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Originally Posted by CraigE

My spigot bush squealed for about 12 months before i changed it and the clutch. It had no real effect other than the noise. When removed the bush was still in fairly good nic just dry, but as out was replaced.
18 months later the box dropped the output shaft bearing, so I had a choice rebuild or buy one. I elected to buy one. As said parts alone were going to be around $700, but that is for a complete rebuild, parts would depend on how far you were going with the rebuild.
The biggest issue is around labour. It would depend on how proficient your gearbox builder would be at the task, but I would envisage you would be looking at around $1000 - $1500 in labour alone in Australia with rates over $100 per hour now.
If you can do a lot yourself you can reduce costs.
I will be having a play with my old box when I get another job and a few dollars to spare, but as I needed the Defender running in case i needed it I just bought a complete rebuilt box out of the UK as was just as economical as getting rebuilt here and cheaper than buying a recon box here.
If just doing the spigot it is cheap, but that is if you can remove and refit. The big cost would be labour.
I have found most R380s to be a little notchy into second, even new.

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Mmmm, mine has been doing it for months now, but not every time I start. I have a Simpson trip in the middle of the year which is why I thought I should do it, but if it will keep going for a while yet, maybe I will save the money. I only use it for weekend trips or touring trips so by the middle of the year it might have done only another 1500 km

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Originally Posted by justinc

Most likely it is the spigot bushing in the back of the crankshaft causing the noise, and if it is really bad, will cause gear selection issues, too. They are very prone to this. Make certain it gets replaced or you will be doing the job again....and yes try some different oil first, 190k is still quite young for these transmissions to think about rebuiling, unless of course it has had a poor service life... :-(

Jc

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Hi JC how do you get the bush out? I tried the grease method to no avail. 2nd method was cut a thread in it.

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Originally Posted by Gillie

Hi JC how do you get the bush out? I tried the grease method to no avail. 2nd method was cut a thread in it.

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By the "grease method" - do you mean making a dowel that just fits inside the bush, then packing the bush with grease and hammering the dowel in?

This method has never failed me. The only way I can see it not working is if your dowel is too small.

The only dowel I had I suspected to be too small. Good to know it works.

Sent from my YOGA Tablet 2 Pro-1380F using AULRO mobile app

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Originally Posted by Gillie

The only dowel I had I suspected to be too small. Good to know it works.

Sent from my YOGA Tablet 2 Pro-1380F using AULRO mobile app

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wrap the dowel in duct tape or electrical tape if it is too small.

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Originally Posted by bitdist

Mmmm, mine has been doing it for months now, but not every time I start. I have a Simpson trip in the middle of the year which is why I thought I should do it, but if it will keep going for a while yet, maybe I will save the money. I only use it for weekend trips or touring trips so by the middle of the year it might have done only another 1500 km

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I probably did 30,000kms with mine squealing when cold. Having said that I certainly dont want to lead you into a false sense of security. The job is a PIA but not hugely difficult.

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Originally Posted by Gillie

Hi JC how do you get the bush out? I tried the grease method to no avail. 2nd method was cut a thread in it.

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A large, flat blade screwdriver, a decent hammer, and chip/ break it out. It breaks up pretty easily and obviously you aren't reusing it ...:D

Time is money... :)

JC

Make sure you check the fit of the new bush on the gearbox input shaft, before you push the new bush home.

Out of the box some new parts can be a disappointment as the fit can be quite sloppy! :(

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Originally Posted by CraigE

I probably did 30,000kms with mine squealing when cold. Having said that I certainly dont want to lead you into a false sense of security. The job is a PIA but not hugely difficult.

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Literally as soon as this thread appeared my 130 has started with the same issues after some big trips.
Is there a tutorial anywhere on here about how to replace the spigot bushing/bearing? Seems common enough problem to warrant it. I'd love to give it a shot if I could.

Thanks in advance for your wise counsel.

You can bust the pilot bush out like JC suggested, or you could use one of these.

Ref; Pilot Gear Bearing Puller 3 JAW Bicycle Motorcycle Automotive Flywheel | eBay

https://www.aulro.com/afvb/images/im...015/01/659.jpg
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