Thread: HELP!!!!!

Has anyone got any diagrams of a R380 5 speed gearbox or can you tell us how to get the shafts out of the box as we are stuck on how to do this ..... help please .

Mick, I haven't pulled down an R380, but most gearboxes are disassembled the same way. The cluster shaft, the one in the bottom of the case with all the gears in one piece has to be dropped to allow the input and mainshaft to be removed. Take the bell housing off and the extension/transfer case off, the Cluster gear shaft is ususally driven out from rear to front, the cluster gear has spacers and thrust washers each end and they will drop into the bottom of the case. Lay the cluster gear in the bottom of the case, remove the front seal housing from the front of the case and remove the input shaft, note how the synchro rings go, you maybe able to slide the synchro hub and selctor off. You maybe able to remove the remainder of the mainshaft out through the rear bearing hole. If not you should take it up and out through the top of the box. Reassembly is a Bit harder, you will need a Dummy shaft for the cluster gear to get it back in place after you have reinstalled the input and mainshaft. the dummy shaft can be made out of metal or wood, it needs to be the same outside diameter of the cluster gear shaft to hold the roller bearings and spacers inside the cluster gear, it has to be the exact length of the inside of the case between the thrust surfaces of the case. It needs to be long enough to hold the spacers and thrust washers on each end of the cluster gear which have been liberally greased up to help hold them in place. You need to have the cluster with the dummy shaft and spacers fitted in place sitting in the bottom of the case while you install the input and mainshaft. When these are assembled you lift (I usually use a couple of thin leather straps) the cluster gear up VERY carefully and line up the bore of the case with the dummy shaft and carefully insert the real shaft pushing out the dummy as you go, it's a bit fiddly and almost impossible without using a dummy shaft, hope this helps, Regards Frank.