R380 Manual Gearbox Overhaul
MANUAL GEARBOX
OVERHAUL
31
Output shaft - Reassemble
1. Clamp output shaft in protected vice jaws,
output end upwards.
2. Fit 2nd gear needle roller bearing, 2nd gear
and synchromesh baulk rings on to output
shaft.
NOTE: Rotate each baulk ring to ensure
they locate onto each other.
3. Assemble the 1st and 2nd synchromesh
selector hub on to output shaft splines, noting
the 2nd gear side marking. Ensure that baulk
ring has located correctly inside hub.
NOTE: Rotate the ring slightly as the hub
is lowered.
4. Fit 1st gear synchromesh baulk rings, needle
roller bearing, 1st gear and bush on to output
shaft ensuring baulk rings locate correctly
inside selector hub.
5. Using LRT-99-002, and a suitable mandrel
positioned on bearing inner race, press on
output shaft taper roller bearing taking care not
to disturb the position of the synchromesh
baulk rings and gears.
6. Check 1st and 2nd gear end-float.
Checking 1st gear end-float
New: 0.05 - 0.20 mm (0.002 - 0.008 in)
Service limit: 0.327 mm (0.012 in)