Content .. 7 8 9 10 ..

R380 GEARBOX. Manual - part 9

MANUAL GEARBOX

OVERHAUL

4. Remove extension from lower gear lever.
5. Remove bolt and special washer securing

lower gear lever.

6. Carefully withdraw lower gear lever from

housing ensuring that spring loaded nylon pad
is retained during removal.

WARNING: Personal injury may result if
pad is not retained.

7. Release nylon pad, recover spring.
8. Clean all components.

Inspection

1. Check lower gear lever ball pin for wear,

replace if necessary.

CAUTION: If lower gear lever is to be
replaced then ball pin seating, located in
remote housing should also be replaced.

2. Check nylon pad and spring for wear and

damage, replace if necessary.

3. Check bias spring roll pin for damage, replace

if necessary.

Reassemble

1. Smear ball pin with multi - purpose grease and

fit spring and nylon pad.

2. Depress nylon pad against spring pressure,

position lower gear lever in housing.

CAUTION: Ensure nylon pad is facing
away from bias spring location.

3. Fit lower gear lever retaining bolt and special

washer, tighten bolt to 15 Nm.

4. Fit extension to lower gear lever.
5. Position roll pin to housing, fit roll pin.
6. Fit bias spring adjusting screws and locknuts.
7. Using a suitable piece of tubing locate both

ends of bias spring over ball pins.

NOTE: Do not adjust bias spring at this
stage.

MANUAL GEARBOX

OVERHAUL

Remote housing - Type A gearbox

Dismantle

1. Remove setscrew securing trunnion to selector

shaft, remove trunnion.

2. Remove and discard circlip securing ball pin

seating to trunnion, remove seating.

3. Slacken locknut, remove 5th gear stop screw.

CAUTION: Retain shim(s).

4. Remove blanking plug from end of remote

housing.

5. Remove setscrew securing quadrant to

selector shaft, remove quadrant.

6. Remove selector shaft from remote housing,

remove and discard ’O’ ring.

7. Remove and discard circlip retaining rollers

and pin to quadrant.

8. Remove pin, recover rollers.

Inspection

1. Check selector shaft and bore in remote

housing for wear.

2. Check quadrant rollers and pin for wear.
3. Check ball pin seating for wear.
4. Replace worn components as necessary.

MANUAL GEARBOX

OVERHAUL

Reassemble

1. Lubricate selector shaft and new ’O’ ring with

gearbox oil.

2. Fit ’O’ ring to selector shaft.
3. Fit shaft to remote housing.
4. Position rollers to quadrant, fit pin and secure

with new circlip.

CAUTION: Ensure that head of pin is on
opposite side of quadrant to selector shaft
boss.

5. Fit quadrant to selector shaft.
6. Apply Loctite 270 to threads of setscrew, fit

and tighten setscrew.

7. Apply Loctite 270 to threads of blanking plug,

fit and tighten plug.

8. Smear ball pin seating with multi - purpose

grease.

9. Position ball pin seating in trunnion, secure

with a new circlip.

10. Position trunnion on selector shaft.
11. Apply Loctite 270 to threads of setscrew, fit

and tighten setscrew.

12. Fit 5th gear stop screw, fit but do not tighten

locknut.

NOTE: 5th gear stop screw adjustment is
carried out during gearbox reassembly.

Gear change housing - Type B gearbox

Dismantle

1. Remove bolts retaining bias springs.

WARNING: To avoid personal injury,
restrain each spring in turn with a pair of
grips while the bolts are being removed.

2. Remove the two springs.

3. Remove remaining bolts to release lower lever

assembly.

4. Remove and discard Railko bush.
5. Remove and discard oil seal.

MANUAL GEARBOX

OVERHAUL

Inspection

1. Check ball cross pin slots in gear change

housing for wear.

2. Check ball and pins for wear.
3. Check bias springs for distortion.
4. Replace worn components as necessary.

Reassemble

1. Apply multi-purpose grease to ball and cross

pins.

2. Apply multi-purpose grease to new Railko bush

and fit to gear change housing.

CAUTION: Ensure that the slots in each
bush are aligned with slots in housing.

3. Lubricate a new oil seal with gearbox oil.
4. Fit oil seal using a suitable mandrel.
5. Position gear lever to gear change housing

ensuring ball cross pins are located in slots in
housing and Railko bush.

6. Position bias spring adjustment plate to gear

change housing,

7. Apply Loctite 270 to threads of 2 short bias

adjustment plate bolts.

8. Fit bolts to secure front of bias adjustment

plate and tighten to 25 Nm.

9. Position bias spring to pillar ensuring longest

end of spring is against gear lever.

10. Apply Loctite 270 to threads of 2 long bias bias

adjustment plate bolts.

11. Restrain bias spring using a suitable pair of

grips,ensure short end of bias spring is
positioned on outside edge of bolt hole.

WARNING: Personal injury may result if
bias spring is not retained.

12. Fit bolt and washer ensuring end of bias spring

is retained beneath washer; tighten bolt to 25
Nm.

13. Repeat procedure for remaining bias spring.

Remote gear change - Type C gearbox

Dismantle

1. Remove 2 bolts and 2 countersunk screws

securing bias spring bridge plates.

2. Remove bridge plates, bridge plate liners and

bias spring.

3. Remove 4 bolts and washers securing bottom

cover plate, remove plate.

4. Remove bolt securing gear lever cap, remove

cap.

5. Remove gear lever, recover anti-rattle spring

and plunger.

6. Remove pinch bolt securing selector rod yoke,

remove yoke.

7. Withdraw selector rod from remote housing.
8. Clean components.

Content .. 7 8 9 10 ..