Discovery II
MANUAL GEARBOX - R380
37-30
OVERHAUL
4. Using tools LRT-37-043, LRT-37-043/2 and
LRT-99-002, press new bearing onto input
shaft.
5. Using tool LRT-99-002 and a suitable mandrel,
fit input shaft outer bearing track to front cover.
6. Fit layshaft bearing track to front cover.
7. Using tool LRT-99-002 and a suitable mandrel,
fit pilot bearing outer track to input shaft.
8. Clean synchroniser hubs, gears and bearings.
9. Position output shaft in protected vice jaws,
output end upwards.
10. Fit 2nd gear bearing, 2nd gear and
synchromesh baulk rings onto output shaft.
11. Position 1st / 2nd synchroniser hub onto output
shaft. Ensure that baulk rings are correctly
located in hub.
12. Position 1st gear synchromesh baulk rings,
needle roller bearing, 1st gear and bearing
collar onto output shaft. Ensure baulk rings are
correctly located in hub.
13. Remove output shaft from vice.
14. Using tool LRT-37-001, LRT-37-044 and
LRT-99-002, press taper bearing onto output
shaft.
15. Using a feeler gauge, check end float of 1st
gear between gear and collar flange:
l
New = 0.05 - 0.20 mm (0.002 - 0.008 in)
l
Service limit = 0.327 mm (0.012 in)
16. Using a feeler gauge, check end float of 2nd
gear between gear and output shaft flange:
l
New = = 0.04 - 0.21 mm (0.0016 - 0.0083
in)
l
Service limit = 0.337 mm (0.013 in)