R380 Manual Gearbox Overhaul
MANUAL GEARBOX
OVERHAUL
27
Synchromesh assemblies - Overhaul
1. Remove spring clips from both sides of
assembly.
2. Remove slippers and separate the hub from
the sleeve.
3. Examine all parts for damage and wear, check
spring clips for tension.
4. Check no excessive radial movement exists
between inner members and output shaft
splines.
5. Examine inner and outer splines for wear.
6. Examine the dog teeth for wear and damage.
NOTE: Example ’A’ shows a tooth in good
condition. Example ’B’ shows the rounded
corners of a worn tooth.
7. Replace unit if excessively worn.
Reassemble
8. Refit inner hub to sleeve.
NOTE: Hubs and sleeves have a master
spline combination and can only be
assembled one way. The sleeves are
further identified with a series of half moon
notches which clearly identify which side of the
assembly faces which gear. Ensure the slot in
the hub aligns with the centre notch on the
sleeve.
Assy
Hub
Sleeve
Against
Gear
1st/2nd
-
1 Notch
1st
2 gear
side
-
2nd
3rd/4th
-
3 Notches
3rd
-
-
4th
5th/Rev
-
5 Notches
5th
9. Fit slippers and secure with a spring each side
of the synchromesh assembly ensuring the
step on each spring locates on a different
slipper.
NOTE: 5th and reverse synchromesh hubs
have different springs which are coloured
yellow.
