Hi Chaps!
Further to!
Got any top tips for changing R380 gearbox and clutch on a 300tdi???
Does front exhaust section have to come off? If so how do you get the kin thing off (3 studs) with out breaking them? Heat?
As it looks like I'l be doing it on mi tod, was thinking of taking transfer box off and have made a gearbox craddle that I can put on a palet truck to lower/higher gearbox.
Ordered clutch plate,housing,bearing & fork doo dar.
What about changing spigot roller bearing in crankshaft?
Any thing else any bod would like to share?
Cheers in advance
Jason
R380 GEARBOX
Remove
The R380 gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
support plate
LRT-99-007.
.
1.
Install vehicle on a ramp.
2.
Disconnect battery.
3.
Remove gearbox carpet.
4.
Remove gear lever and transfer box lever knobs.
5.
Remove gear lever cover.
6.
Remove nut and washer securing gear lever.
7.
Mark gear lever spline setting and remove lever
and gaiter from the splined lower gear lever.
8.
Release insulation pad from tunnel cover and
gear levers and remove.
9.
Select low range on transfer box lever to prevent
lever from fouling tunnel when removing gearbox
37
MANUAL GEARBOX
2
REPAIR
10.
Remove 3 trim studs and lift up handbrake
gaiter.
11.
Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
12.
Drain cooling system See COOLING SYSTEM,
Adjustment, Drain and refill cooling system .
13.
Remove viscous fan unit See COOLING
SYSTEM, Repair, Viscous coupling and fan .
14.
Slacken retaining clip and disconnect radiator
top hose at thermostat housing.
15.
Slacken retaining clip and disconnect intake
hose at induction manifold. If EGR system is
fitted, slacken 2 retaining clips and disconnect
intake hose at intercooler.
16.
Slacken retaining clip and disconnect hose at
turbocharger.
17.
Remove bolt securing transmission breather
pipe clip to rear of engine.
18.
Release breather pipes.
19.
Release ties securing gearbox harness to
breather pipes.
20.
Raise vehicle on ramp.
21.
Position a suitable container under transmission
and drain main gearbox and transfer box See
SECTION 10, Maintenance, Under vehicle
maintenance .
22.
Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
23.
Remove 4 nuts and disconnect propeller shaft
from transfer box.
MANUAL GEARBOX
REPAIR
3
24.
Remove 2 bolts, withdraw clutch slave cylinder
and backing plate from bell housing, and tie
aside.
25.
Mark rear propeller shaft drive flange and
transmission brake drum for reassembly.
26.
Remove 4 nuts, disconnect propeller shaft from
brake drum, and tie aside.
27.
Remove front pipe from exhaust manifold See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe .
28.
Remove intermediate silencer. See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90 or See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 110/130
29. Temporarily support transmission.
30.
Remove nut securing gearbox LH mounting
rubber to chassis crossmember.
31.
Remove 4 nuts and bolts securing crossmember
to chassis longitudinals.
32.
Remove nut securing transfer box mounting
rubber to RH side of crossmember.
33.
Remove 4 nuts and bolts securing crossmember
to chassis longitudinals.
34.
With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
35.
Remove chasss crossmember.
36.
Remove 4 bolts from both sides and remove LH
and RH mounting brackets.
37
MANUAL GEARBOX
4
REPAIR
37.
Pull handbrake cable through heel board and tie
aside.
38.
Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39.
Release speedometer cable from retaining clip
on transfer box.
40.
Remove retaining nut and release battery earth
strap from transfer box.
41.
Secure manufactured cradle LRT-99-007 to a
suitable hydraulic hoist.
42.
Raise hoist and secure to gearbox with 3 bolts in
location provided.
43.
Lower hoist sufficiently to allow transfer lever to
clear transmission tunnel aperture.
44.
Disconnect differential lock switch and reverse
light connectors.
45.
Remove bolt and release earth leads from RH
side of transfer box.
46.
Support engine under sump with a jack.
47.
Remove 14 bell housing to engine fixings.
48.
Withdraw transmission whilst ensuring all
connections to engine and chassis are released.
49.
Lower hoist and remove gearbox assembly.
MANUAL GEARBOX
REPAIR
5
Separating transfer gearbox from main gearbox
50.
Remove transmission assembly from hoist
cradle and position safely on a bench.
51.
Remove breather pipes. Discard pipe union
sealing washers.
52.
Remove ’Nyloc’ nut, and remove bolt, securing
lever to high/low shaft.
53.
Collect spacer washer.
54.
Remove 2 clips and remove differential lock
lever link.
55.
Remove lower locknut from high/low operating
rod.
56.
Place a sling round transfer box and attach to
hoist.
57.
Remove nut and 4 bolts securing transfer
gearbox to extension housing.
58.
Withdraw transfer gearbox.
Assembling transfer gearbox to main gearbox
59.
Clean extension housing and transfer gearbox
mating faces.
60.
Ensuring loose upper dowel is fitted, hoist
transfer gearbox into position.
61.
Secure transfer box to extension housing.
Tighten fixings to 40 Nm (30 lbf/ft).
62. Connect high/low operating rod, fit and tighten
locknut.
63.
Fit link to differential lock lever and secure with 2
clips
64.
Align lever to high/low shaft, position washer, fit
bolt and new Nyloc nut. Tighten to 2 Nm (1.5
lbf/ft).
65. Position breather pipes, secure pipe unions
using new sealing washers. Tighten unions to 15
Nm (11 lbf/ft).
Fitting transfer gearbox and main gearbox
assembly
66. Position transmission assembly to hoist cradle.
67.
Clean bell housing and engine mating faces.
Apply sealant to both mating faces.
68.
Temporarily fit gear lever and select any gear in
main gearbox to facilitate entry of gearbox input
shaft. Engage low range.
69.
Position and raise hoist, fit transmission to
engine whilst keeping harness and pipes clear to
prevent trapping.
70.
Secure transmission to engine. Tighten fixings to
45 Nm (33 lbf/ft).
71.
Secure earth leads to RH side of transfer box.
72.
Connect reverse lamp switch connectors and
differential lock switch connectors.
73.
Secure breather pipes to harness with clips.
74.
Remove support from engine sump.
75.
Position temporary support under transmission.
76.
Secure LH and RH mounting brackets to
gearbox. Tighten fixings to 55 Nm (41 lbf/ft).
77. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
37
MANUAL GEARBOX
6
REPAIR
78.
Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79.
Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaing clip
to LH top bolt.
80.
Fit intermediate silencer. See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90 or See MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81.
Fit front pipe to exhaust manifold See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe .
82.
Fit rear propeller shaft to transmission brake
drum. Tighten nuts to 47 Nm (33 lbf/ft).
83. Remove 3 bolts securing support cradle to
transmission and remove hoist.
84.
Reconnect battery earth strap to transfer box
fixing.
85.
Connect speedometer cable to transfer box and
secure with retaining clip.
86.
Coat both sides of clutch slave clinder backing
plate with Hylomar P232M waterproof sealant.
87.
Locate backing plate on slave cylinder.
88.
Fit slave cylinder to bell housing, engaging
push-rod through centre of dust cover, and with
bleed screw uppermost. Tighten bolts to 25 Nm
(18 lbf/ft).
89. Fit front propeller shaft to transfer box. Tighten
nuts to 47 Nm (33 lbf/ft).
90. Refill main gearbox and transfer box See
SECTION 10, Maintenance, Under vehicle
maintenance .
91.
Feed transmission brake cable through heel
board and ensure grommet is correctly located.
NOTE: Apply a soap solution to aid fitment
of cable.
92.
Lower vehicle on ramp.
93.
Fit ties to secure gearbox harness to
transmission breather pipes.
94.
Fit breather pipe retaining clip to rear of engine.
95.
Reconnect charge air hose at turbocharger.
96.
Reconnect intake hose at induction manifold. If
EGR system is fitted, reconnect intake hose at
intercooler.
97.
Reconnect radiator top hose at thermostat
housing.
98.
Fit viscous fan unit See COOLING SYSTEM,
Repair, Viscous coupling and fan .
99.
Reconnect battery.
100.
Refill cooling system See COOLING SYSTEM,
Adjustment, Drain and refill cooling system .
101.
Connect cable clevis to handbrake lever and fit
handbrake gaiter.
102.
Locate insulation pad over gear levers and fit to
tunnel cover.
103.
Fit gear lever with gaiter to lower lever spline
and secure with retaining nut.
104.
Fit gear lever cover.
105.
Fit gear lever and transfer box lever knobs.
106.
Fit gearbox cover carpet.
107.
Check operation of handbrake and adjust as
necessary See SECTION 10, Maintenance,
Under vehicle maintenance .
MANUAL GEARBOX
SPECIFICATIONS, TORQUE
1
TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Slave cylinder to bell housing .................................................................... 25
Breather ..................................................................................................... 15
Bell housing to cylinder block ..................................................................... 40
High/low level to shaft ................................................................................. 2
Transfer box to gearbox ............................................................................. 45
NOTE: Torque values below apply to all screws and bolts used unless otherwise specified.
METRIC Nm
M5 ...................................................................................................... 6
M6 ...................................................................................................... 9
M8 ..................................................................................................... 25
M10 ................................................................................................... 45
M12 ................................................................................................... 90
M14 .................................................................................................. 105
M16 .................................................................................................. 180
UNC / UNF
1/4 ...................................................................................................... 9
5/16 ................................................................................................... 24
3/8 ..................................................................................................... 39
7/16 ................................................................................................... 78
1/2 ..................................................................................................... 90
5/8 .................................................................................................... 136
Look throught this m8, hopefully it helps
Regards
Riggaz
