R380 Rebuild

Now that that was sorted, time to install lay shaft nut and finish off rear extension housing section.

Conical split washer installed in lay shaft 5th gear:

http://www.aulro.com/afvb/attachment...0&d=1402008066


Home made anti-rotation tool to enable tigthening of lay shaft nut:

http://www.aulro.com/afvb/attachment...1&d=1402008107


Lay shaft nut installed to 220Nm and staked into groove:

http://www.aulro.com/afvb/attachment...2&d=1402008142


Main shaft rear support bearing track drifted into position (this is Ashcrofts HD version):

http://www.aulro.com/afvb/attachment...3&d=1402008178

Thrust segments installed:

http://www.aulro.com/afvb/attachment...d-p1010623.jpg


Retaining ring installed over thrust segements:

http://www.aulro.com/afvb/attachment...6&d=1402008914


Pic showing the new replacement control ring from Ashcrofts (looks to be made from Phenolic?) NB: This part gets installed into the rear extension housing!:

http://www.aulro.com/afvb/attachment...9&d=1402009020


Detent ball, spring and plug fitted. Loctite 290 and tightend to 25Nm:

http://www.aulro.com/afvb/attachment...0&d=1402009118

There are still a couple of things to do before installing the rear extension housing (lay shaft bearing track, oil filter, oil control ring etc) , but I wanted to do a dry fit and check a few things before that.

As the extension housing had one of the mounting ears snapped off, I wanted to replace it. After a few phone calls and web searching, the easiest and cheapest was Ashcrofts. I asked if they would be able to do their HD rear bearings upgrade and they were happy to do so. As I also ordered a new oil pump and seal, I was pleasantly suprised to have the extension housing and parts turn up and already assembled. Typical of Ashcofts excellent work and service! :)

The extension housing as I received it:

http://www.aulro.com/afvb/attachment...6&d=1402010535

http://www.aulro.com/afvb/attachment...2&d=1402010343


Dry fitting the extension housing:

http://www.aulro.com/afvb/attachment...4&d=1402010378


Dry fitting the selector quadrant to check the operation of gear selection:

http://www.aulro.com/afvb/attachment...5&d=1402010457

Since all gears selected and turned without problem (phew!!) I could finish off the last few bits inside the extension housing.

The HD bearing for the layshaft has a bush installed inside the bearing track. The height of the bush is shorter than the height of the bearing track and is flush with the top, not the bottom. Normally the bottom of a bearing track would seat onto the shoulder of the shaft. I did not want to make any assumptions, so took these 2 pictures and emailed Dave Ashcroft. Of coarse all was good and just a matter of seating it hard down like a normal version.

Layshaft HD bearing track:

http://www.aulro.com/afvb/attachment...8&d=1402011394

http://www.aulro.com/afvb/attachment...7&d=1402011339


Oil filter install:

http://www.aulro.com/afvb/attachment...0&d=1402011472


Oil pump pick up pipe installed, oil control ring installed and sealant applied:

http://www.aulro.com/afvb/attachment...2&d=1402011520


NB: there is a little tag on the LR oil control ring and a little steel pin on the Ashcroft version. Either of these locate into a check out in the housing (you can just see it in the above pic, facing towards the oil pick up pipe). Make sure you face the oil control ring the correct way out so it seats over the thrust segments and retaing ring when the extension housing is installed.

Lower the extension housing onto the main case assembly. making sure that #1, you have the flats on the end of the layshaft lined up with the flats in the oil pump drive, and #2 the oil pump pick up pipe is going into the oil filter. If needed you can rotate the main shaft to turn the layshaft to line it up with pump.

The extension housing may need a gentle tap for the last 2-3mm but other than that you should not need to force it. DO NOT force it. (dont forget to remove the dummy/slave bolts that were holding the centre plate to main case if you havent already)

Extension housing installed, all 8mm bolts torqued to 25nm with loctite 290.

http://www.aulro.com/afvb/attachment...5&d=1402012519


Interlock spool retainer and O ring fitted, nut torqued to 8Nm (it does not say to use loctite in the WSM. I chose to)

http://www.aulro.com/afvb/attachment...d-p1010653.jpg


Quadrant selector installed, grub screw torqued to 25Nm with loctite 290.( I installed this at this point to double check the selection of gears before going further or letting sealant and loctite dry):

http://www.aulro.com/afvb/attachment...9&d=1402012608

Very nice rebuild! Did you messure the rear bearings? I'm just wondering what bearings are used in the HD version.

Dear Uninformed, thankyou for a very informative tutorial, one I hope I don't need anytime soon. But Like you I'll probably buy a spare 380 and replace mine before it's wrecked inside. I'll be changing out my transfer case first. I hear some of them go very long distances , but mine has 200,000 kms, and is leaking at the intermediate shaft. Great pictures as well. :)

cheers simmo.

Our R380 is getting fitted back in right now, we lost first gear:confused: only done 120,000 approx. but we do tow a car trailer an awful lot :);)

Mrs hh:angel:

Uninformed, a question, how did you get the casings so clean?
did you boil them in caustic or have them blasted etc.

I'm interested to know, when i do my T case , as you know cleanliness is next to godliness when working on gearboxes etc, plus I'd like the job to look like a new one when its done.
chhers

Serg would have put it into the big front loader with his thongs. :)

Great thread!

cheers, DL