Synchroniser - gearbox - set

20. Check end float of 3rd gear between gear and flange on output shaft: l New = 0.11 - 0.21 mm (0.004 - 0.0083 in) l Service limit = 0.337 mm (0.013 in)
21. Check output shaft and layshaft end float as follows.
22. The end float setting for both shafts is: l New = 0.00 to 0.05 mm (0.0 to - 0.002 in) l Service limit = 0.05 mm (0.002 in)
23. Fit front cover to gearbox case without the oil seal and tighten bolts by diagonal selection to 25 Nm (18 lbf.ft).
24. Position in vice with front cover facing downwards.
25. Fit input shaft to gearbox case less 4th gear baulk ring.
26. Fit output shaft assembly to input shaft.
27. Fit output shaft bearing track and shim to centre plate.
28. Fit centre plate to gearbox case and secure using 8 slave bolts.
29. Rotate output shaft to settle bearings.
30. Fit a suitably large ball bearing into end of output shaft.
31. Position a suitable DTI and zero probe on ball bearing.
32. Lift output shaft and note DTI reading.
33. If reading is incorrect, dismantle and fit shim to give correct end float.
34. Repeat above procedure.
35. Repeat procedure for layshaft end float.
36. Remove and discard 6 bolts and remove gearbox front cover.
37. Fit gearbox selector fork - set. MANUAL GEARBOX - R380, OVERHAUL, Fork - set - selector shaft.
38. Fit gearbox front cover. MANUAL GEARBOX - R380, OVERHAUL, Cover - front.

Synchroniser - gearbox - set

$% 37.20.07

Disassembly

1. Remove gearbox selector fork set. MANUAL GEARBOX - R380, OVERHAUL, Fork - set - selector shaft.

2. Using tool LRT-99-002 and support bars under 1st gear, press output shaft bearing from output shaft.

3. Remove 1st gear, bearing collar, needle roller bearing and synchromesh rings.

4. Noting its fitted position, remove 1st / 2nd gear synchroniser hub, 2nd gear synchromesh rings, 2nd gear and needle roller bearing.