Thread: R380 Rebuild

Pinion shaft installed:




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:




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:




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




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

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:




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:




Interlock spool just off centre in the hole:




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




Splash shield installed. Bolts to 8 Nm:

Reverse idler gear ready for assembly:




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




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




Main shaft bush installed:

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:




Reverse gear cleaned and looking ok:




Reverse gear installed on main shaft:




Layshaft reverse gear cleaned and looking ok:

Layshaft reverse gear and Baulk ring installed:




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




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




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:

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.




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




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




Both 5th gears installed:

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. simmo

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. simmo

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