Premature wear synchromesh components

PREMATURE WEAR SYNCHROMESH COMPONENTS

Model

New Range Rover R380 Manual Gearbox Range Rover Classic R380 Manual Gearbox Discovery R380 Manual Gearbox Defender R380 Manual Gearbox

Affected vehicles

325427 onwards 663123 onwards 178922/509575 onwards 976883 onwards

Date

1995-11-22

Reference

22/11/95

Bulletin text

Premature Wear Synchromesh Components

MODEL

New Range Rover R380 Manual Gearbox Range Rover Classic R380 Manual Gearbox Discovery R380 Manual Gearbox Defender R380 Manual Gearbox

DETAIL

From the above Vin numbers and Gearbox number 55A0416034J all factory built R380 gearboxes are fitted with a revised design of synchromesh components. The revisions are intended address premature wear of synchro hubs and 1st, 2nd, and 3rd synchro rings, these revisions will address up shift ‘snick’ into 2nd and 3rd gear, also 5th to 4th gear block out. The component changes and part number changes detailed overleaf form a complete package and should not be interchanged with old parts unless specified elsewhere in this bulletin.

ACTION REQUIRED

Information only: When effecting repairs to R380 gearboxes built prior to these changes refer to repair notes overleaf.

PARTS INFORMATION

See overleaf

PROCEDURE

Refer to the workshop manual section 37 manual gearbox

22/11/95 37/08/95/EN

AFFECTED VEHICLES

LP 325427 onwards LH 663123 onwards LJ 178922/509575 onwards LD 976883 onwards

WARRANTY

Not applicable

COMP. CODE

Not applicable

SRO

Not applicable

Premature Wear Synchromesh Components

MODEL

New Range Rover R380 Manual Gearbox Range Rover Classic R380 Manual Gearbox Discovery R380 Manual Gearbox Defender R380 Manual Gearbox

PARTS CHANGES LIST OLD NEW Synchro Assemblies

1st and 2nd FTC 2733 FTC 5100 3rd and 4th FTC 2887 FTC 5101 5th and Reverse FTC 2727 FTC 5102

4th and 5th Gear Baulk Ring

FTC 2731 FTC5018

Inner Synchro Ring

FTC 2397 FTC 5019

Mainshaft Gears

1st Gear 31T FTC 2716 FTC 5036 1st Gear 32T FTC 2948 FTC 5037 2nd Gear 27T FTC 2714 FTC 5038 2nd Gear 28T FTC 4166 FTC 5040 2nd Gear 32T FTC 4159 FTC 5039 3rd Gear 27T FTC2712 FTC 5041

Primary Pinion Gears

FTC 3928 FTC 5044 FTC 3927 FTC 5046 FTC 3933 FTC 5048 FTC 4068 FTC 5050 FTC 4070 FTC 5052 FTC 3366 FTC 5056

22/11/95 37/08/95/EN

AFFECTED VEHICLES

LP 325427 onwards LH 663123 onwards LJ 178922/509575 onwards LD 976883 onwards

Repair Action

Where a repair is being carried out on a Gearbox built prior to this modification, original performance can be restored by changing the following parts only

5th to 4th Block out - Replace 4th gear baulk ring FTC 2731 with FTC 5018

Premature Wear of 1st 2nd or 3rd Gear Synchro’s and “upshift snick”

-Replace outer baulk ring FTC 3584 -Replace Intermediate ring FTC 2396 -Replace inner ring FTC 2397 with FTC 5019 -Replace 1st/2nd Synchro assembly FTC 2733 with FTC 5100 and -Replace 3rd/4th Synchro assembly FTC 2887 with FTC 5101

NOTE:

Full performance to the latest specification can only be achieved retrospectively by changing all affected parts including primary pinion and mainshaft gears.

New parts must not be mixed with old parts except as specified above