Thread: R380 Rebuild

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




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




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):




TRB installed down to collared bush:

Flip main shaft over to start on the other end:




Install needle rollar bearing:




3rd gear looking good:




3rd gear installed:

Inner baulk ring installed:




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




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




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!)

Synchro selector assembly installed:




Stepped spacer installed:




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




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

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.




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




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

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:




End plate bolted up to main housing:




Input shaft installed into its bearing track:




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

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:




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




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:




Layshaft, TRB track and shim installed:




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