R380 Rebuild

Outer baulk ring installed ( this is the one I missed before, note they are installed mirror to the previous side):

http://www.aulro.com/afvb/attachment...7&d=1399200824


Inner metal ring:

http://www.aulro.com/afvb/attachment...2&d=1399201019


Inner baulk ring:

http://www.aulro.com/afvb/attachment...3&d=1399201069


Cleaned 1st gear looking good also:

http://www.aulro.com/afvb/attachment...4&d=1399201118

1st gear installed, making sure to locate the three lugs on the inner metal ring:

http://www.aulro.com/afvb/attachment...2&d=1399202181


1st gear needle roller bearing installed (note its much larger ID than main shaft):

http://www.aulro.com/afvb/attachment...4&d=1399202238


Collared bush installed (this has a oil groove and hole inside it that run on main shaft, the OD of this bush goes inside the needle roller bearing):

http://www.aulro.com/afvb/attachment...5&d=1399202280


TRB installed down to collared bush:

http://www.aulro.com/afvb/attachment...6&d=1399202319

Flip main shaft over to start on the other end:

http://www.aulro.com/afvb/attachment...4&d=1399203659


Install needle rollar bearing:

http://www.aulro.com/afvb/attachment...5&d=1399203735


3rd gear looking good:

http://www.aulro.com/afvb/attachment...7&d=1399203841


3rd gear installed:

http://www.aulro.com/afvb/attachment...8&d=1399203881

Inner baulk ring installed:

http://www.aulro.com/afvb/attachment...2&d=1399204664


Inner metal ring installed (again, 3 tabs locate in 3 slots in 3rd gear):

http://www.aulro.com/afvb/attachment...3&d=1399204729


Outer baulk ring installed (again, locating over 3 tabs on inner baulk ring):

http://www.aulro.com/afvb/attachment...4&d=1399204776


Synchro selector assembly ready for install (note 3 semi circles in lower outer edge! These are to go TOWARDS 3rd gear. Again this assembly can only go together one way, can only be installed one way and is gear specific!)

http://www.aulro.com/afvb/attachment...6&d=1399204822

Synchro selector assembly installed:

http://www.aulro.com/afvb/attachment...9&d=1399205493


Stepped spacer installed:

http://www.aulro.com/afvb/attachment...0&d=1399205529


TRB installed down onto spacer (this is the small bearing that goes into the end of the Input shaft):

http://www.aulro.com/afvb/attachment...1&d=1399205567


At this point it all should look something like this (of coarse I could have made a mistake anywhere along the lines :D )

http://www.aulro.com/afvb/attachment...2&d=1399205611

Next thing to do before going any further is to check end float of each gear on the main shaft.

1st gear should be between 0.05-0.20mm (new), service limit 0.327mm.

http://www.aulro.com/afvb/attachment...3&d=1399288220


2nd gear should be between 0.04-0.21mm (new), service limit 0.337mm

http://www.aulro.com/afvb/attachment...4&d=1399288282


3rd gear should be between 0.11-0.21mm (new), service limit 0.337mm

http://www.aulro.com/afvb/attachment...5&d=1399288363

Now we have to do a dummy set up to check end float of shafts in the main case. This requires the end plate to be installed on the main case (NO oil seal!), and to check one shaft at a time (the Input and main shafts are considered one)

Input shaft bearing track installed in end plate:

http://www.aulro.com/afvb/attachment...6&d=1399288935


End plate bolted up to main housing:

http://www.aulro.com/afvb/attachment...7&d=1399288985


Input shaft installed into its bearing track:

http://www.aulro.com/afvb/attachment...8&d=1399289277


Main shaft as assemebled so far, installed into end of input shaft:

http://www.aulro.com/afvb/attachment...9&d=1399289371

Remeber those shims that were installed on bearing tracks as the centre plate was removed, nows the time to grab them.

Main shaft bearing track and its shim with centre plate:

http://www.aulro.com/afvb/attachment...0&d=1399290044


Install the bearing track and shim on shaft, install centre plate and bolt up using 8mm dummy bolts.

Dial guage set up to check end float. 0.00-0.05mm (new), service limit 0.05mm

http://www.aulro.com/afvb/attachment...1&d=1399290237


Remove and repeat as nessecary to achieve correct end float. Shims are available to buy.

NOTE: the figures Ive been giving are for Suffix K and later boxes. Always check the WSM, dont trust some bum on the internet ;)

Once the main shaft is good and sorted, remove centre plate, main and input shafts.

Layshaft bearing track installed in end plate:

http://www.aulro.com/afvb/attachment...2&d=1399291186


Layshaft, TRB track and shim installed:

http://www.aulro.com/afvb/attachment...3&d=1399291356


Centre plate dummy bolted up and checking end float. 0.00-0.05mm (new), service limit 0.05mm


http://www.aulro.com/afvb/attachment...4&d=1399291401

Time to do some case assembly.

Centre plate input side face up. Installed bearing tracks and shims:

http://www.aulro.com/afvb/attachment...1&d=1399369616


Selector shaft indent ball and spring installed (a small dab of grease will hold ball in place):

http://www.aulro.com/afvb/attachment...3&d=1399370126


Selector shaft, forks and interlock spool assembled in correct position for install ( I hope!!)

http://www.aulro.com/afvb/attachment...2&d=1399369724


You have to install the selector assembly onto the synchro sleeves on the main shaft assembly, making sure both synchro units are not engaging any gears, and offer them both up to the centre plate as one. Line the pin in the selector shaft with the slot in the centre plate. Its a bit fiddly with the selector shaft wanting to slide up as you drop the assembly down into the centre plate. Be careful not to knock the top synchro assembly off/apart. Also be careful to keep it all aligned as before offering it in to centre plate.

Both main shaft and synchro assembles installed into centre plate:

http://www.aulro.com/afvb/attachment...4&d=1399370174