Thread: R380 Rebuild

Originally Posted by worane

Wow! What a fantastic tutorial. If I tried to do that I would have half a dozen parts left over.
I can understand now why they cost so much to repair.
Thank you for taking the trouble to film it all for us lesser mortals.

Even more impressive is that it was the first time Serg had attempted something like that.

Just shows what can be done by asking questions, taking your time, having the manual beside you and thinking things through, it really is a very good effort.

Originally Posted by uninformed

Removing main shaft collar:




Part of my home made anti-rotation tool:

Greetings from the USA. I'm interested in learning more about the tool you are using to remove the main shaft collar. I'm in a situation that I mistakenly loosened and removed the extension housing (1995 Petrol Disco w/R380) while removing the transfer case and the Land Rover manual seems to leave a lot of things to the imagination. I like the job you did with your process of rebuilding, however you are the only one I've seen documented so well. It looks like my transmission is close to what you have, but maybe not exact. I've posted a picture of mine and wanted to see what you think. I just need to get the extension housing re-fitted which I assume would involve removing the oil collar to start? Once removed, from what I've read it just presses back on? Is that fully pressed on - through the oil seal; or does the oil seal press in afterwards?

Thanks in advance - Dave in Virginia.

The correct way to remove the extension housing is to remove the main shaft collar first. Then when you pull the extension housing off, the bearing and plastic ring stay mounted in the extension housing.

To refit now, the bearing and plastic ring need to be refitted to the extension housing. The bearing track only is fitted to the main shaft.

Originally Posted by Judo

The correct way to remove the extension housing is to remove the main shaft collar first. Then when you pull the extension housing off, the bearing and plastic ring stay mounted in the extension housing.

To refit now, the bearing and plastic ring need to be refitted to the extension housing. The bearing track only is fitted to the main shaft.

Thanks Judo. Right, for me, it was a combination of being overly eager and under-informed which got me to this point. But in order to move forward, I expect that once I'm able to remove the collar from the shaft, that the bearing and the oil control ring should slide off the shaft by hand (ie, not a press fit)? Are they a press fit into the extension housing? Thanks for your help on this!

Yes the bearing and oil control ring will come off the shaft easily once the collar is removed. The bearing track will remain in place like the one on the layshaft.

The bearing and oil control ring can be gentled tapped into the extension housing without a press.

Just like to thank you for the information in this post as I am thinking of changing my Gear box from an LT95 to either an R380 or an Isuzu MSA5 gear box .
Thanks again Brad

Originally Posted by Judo

Yes the bearing and oil control ring will come off the shaft easily once the collar is removed. The bearing track will remain in place like the one on the layshaft.

The bearing and oil control ring can be gentled tapped into the extension housing without a press.

Thank you so much. The manual leaves a lot of questions unanswered and since I have never done it before, I only have one last question for now. Upon reinstallation of the oil seal collar, I realize it gets pressed on. Since I don't have the Land Rover tool, how far into/onto the shaft does it get driven? One of the diagrams I saw depicts it protruding slightly as opposed to being completely flush with the rear of the extension housing. I assume if you were using the tool, then you would simply bottom it out, so I essentially just need to know how far to press the collar onto the shaft. Thank you again...

Well my rebuild is in progress and the only thing left is extension housing and collar, so I haven't done that bit yet! But from what I can see the collar will bottom out on the bearing track. This will leave part of the groove protruding past the outside of the housing - as this groove is how you pull it off.

Also, I've found the workshop manual pretty good. Terminology was a struggle at first, but now I've got my head around it all it's OK. The special tools are tricky sometimes, because as you say they don't specify edge protrusion/clearances when installing things like seals without the special tool. But most are fairly obvious once you're in the process of installing it.

Plus, threads like this one (thanks Serg) are priceless. If you search for the various rebuild threads on here there is a picture for almost everything. Brilliant.