R380 Rebuild

Next is the layshaft. You have to lift up the main shaft and selector assemblies and angle the layshaft in so as to clear the bottom bearing. Its a bit tricky, 3 or 4 hands would help :D

Layshaft installed:

http://www.aulro.com/afvb/attachment...6&d=1399371693


Another angle showing selector assembly:

http://www.aulro.com/afvb/attachment...7&d=1399371756


Note height of selector shaft at centre plate (middle indent):

http://www.aulro.com/afvb/attachment...8&d=1399371802


Don't forget to install 4th gear baulk ring. It is only one outer ring as opposed to the earlier 3 piece set ups:

http://www.aulro.com/afvb/attachment...9&d=1399371873

Pinion shaft installed:

http://www.aulro.com/afvb/attachment...2&d=1399373330


It doesn't say this in the WSM, but I figured it couldn't hurt. I did a dry run of end plate and case install. I just fitted it up (no oil seal, no sealant, no bolts to centre plate) and made sure everything turned ok.

Dry run:

http://www.aulro.com/afvb/attachment...3&d=1399373368


Once that was ok, remove case and end plate. It says in the WSM to install oil seal DRY. Who am I to argue

Installed main shaft oil seal and sealant:

http://www.aulro.com/afvb/attachment...4&d=1399373487


End plate installed onto case. 25Nm for the 6 bolts + Loctite 290:

http://www.aulro.com/afvb/attachment...5&d=1399373541


Flipped case over and checked for sealant "ooze" Note oil passage at 12 o'clock above main shaft TRB track:

http://www.aulro.com/afvb/attachment...6&d=1399373608

It says in the WSM to apply sealant to the centre plate. With the case at a good height and no gears etc in the way, I figured it easier to apply it to the case.

Case ready:

http://www.aulro.com/afvb/attachment...7&d=1399376633


Install the case and if you can, install the 8x 8mm dummy bolts before flipping over. Finger tight is enough.

Case flipped and dummy bolts tightened to 25 Nm:

http://www.aulro.com/afvb/attachment...8&d=1399376686


Interlock spool just off centre in the hole:

http://www.aulro.com/afvb/attachment...0&d=1399376985


Interlock spool retainer bolted in. (These have a O ring from factory, but some use sealant on rebuild) Bolts to 8 Nm:

http://www.aulro.com/afvb/attachment...2&d=1399377058


Splash shield installed. Bolts to 8 Nm:

http://www.aulro.com/afvb/attachment...1&d=1399377023

Reverse idler gear ready for assembly:

http://www.aulro.com/afvb/attachment...3&d=1399378226


Installed and checking for end gap. 0.04-0.38mm (new), service limit 0.38mm:

http://www.aulro.com/afvb/attachment...4&d=1399378261


Main shaft reverse gear selective washer installed (hard to see but its there on the shaft, on top of TRB ):

http://www.aulro.com/afvb/attachment...8&d=1399378646


Main shaft bush installed:

http://www.aulro.com/afvb/attachment...5&d=1399378297

This rebuid got delayed by a couple small parts and some tech needed for the HD bearing install.

All good and moving forward now.

Installed reverse gear needle roller bearing on main shaft:

http://www.aulro.com/afvb/attachment...d-p1010564.jpg


Reverse gear cleaned and looking ok:

http://www.aulro.com/afvb/attachment...d-p1010565.jpg


Reverse gear installed on main shaft:

http://www.aulro.com/afvb/attachment...d-p1010569.jpg


Layshaft reverse gear cleaned and looking ok:

http://www.aulro.com/afvb/attachment...d-p1010570.jpg

Layshaft reverse gear and Baulk ring installed:

http://www.aulro.com/afvb/attachment...5&d=1401966671


Selector hub cleaned and rebuilt. NB 5 semi-circles cast into the outer ring edge:

http://www.aulro.com/afvb/attachment...6&d=1401966710


Next you have to install the interlock spool, selector fork and selector hub as one unit:

http://www.aulro.com/afvb/attachment...7&d=1401966954


NB: The WSM states to face the 5 semi-circles towards 5th gear. This would have them face up. When I stripped my gearbox down, they were facing down towards reverse. I have also confirmed this with another member that had the same. I installed mine as it was pulled out, that is the 5 semi-circles facing down towards reverse gear.

Selector fork and interlock spool should look something like this:

http://www.aulro.com/afvb/attachment...8&d=1401967021

Install circlip in groove in mainshaft and check end gap. WSM has 0.005-0.055mm. This gap is adjusted by the selective washer fitted in post #34, 3rd photo down. You can get these in various thicknesses.

http://www.aulro.com/afvb/attachment...2&d=1401967886


5th gear main shaft needle roller bearing and baulk ring installed:

http://www.aulro.com/afvb/attachment...3&d=1401967952


Lay and main shaft 5th gears cleaned and looking ok:

http://www.aulro.com/afvb/attachment...4&d=1401968002


Both 5th gears installed:

http://www.aulro.com/afvb/attachment...5&d=1401968048

An awesome body of work and technical writing, well done, Gearboxes frighten me, you explanation gives me some confidence it can be done at home. I hope there's more coming. :cool: simmo

Quote:

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Originally Posted by simmo

An awesome body of work and technical writing, well done, Gearboxes frighten me, you explanation gives me some confidence it can be done at home. I hope there's more coming. :cool: simmo

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No worries, this is my first rebuild. Just have a half decent digital camera and the WSM and you should be fine.

Now im posting this sort of out of order pic to point out a problem I came across.

There are 2 piece "thrust segment" and retaining ring to go on the main shaft and these locate just above 5th gear in a machined groove. See post #37, 4th photo down to see groove in main shaft above 5th gear.

Luckly I was trying a step or two ahead before I would do things like final nuts or sealant. I could not get my thrust segments into the groove. 5th gear was to "high" up the main shaft. I tried the old thrust segments that came out of this box, they would not work either.

Given the last main set point was the circlip above reverse gear, and that that was ok, I could only put it down to the new baulk ring. I tried gently tapping to seat 5th gear in it and could not get it down. I then installed one of the old baulk rings that were still in ok condition. No probelms and thrust segments slipped straight in.

When I removed 5th gear and flipped it over to see the cone and location of baulk ring, there was a good 0.75~1mm height difference in how the new and old baulk ring would seat on the cone.

Picture showing "thrust segements" installed just above 5th gear:

http://www.aulro.com/afvb/attachment...6&d=1402007682