Just took the engine out of a 1996 300 Tdi 110 to change the clutch, noticed from inside the bell housing a leak around the mainshaft - feeling all pleased with myself for having ordered a front cover seal, took out the 6 cover bolts and as I removed the cover the lay shaft bearing fell out (of the cover) these are held in with a sort of circlip. The Main Bearing is held in but the Layshaft wobbles about and could have been the rattle reported when clutch was released - I am guessing either the bearing is knackered or the cover - any idea which or how to find out???
I assume you can't change half a bearing so is this a gearbox out job if the bearing. - Have a video so will try and post but all comments are welcome as never played with a r380 before.
Always when you think you are there......
Should the layshaft bearing moving in the end cover??


Bearing measured and seems ok

Just received a new front cover with new bearing and I can't believe it - it is the same - I am guessing they must be designed to be loose fir but seems odd - a week lost ahhh try and put it back together now!

All back and running - new clutch will need a bit of pedal adjustment - rattle still there - must be a design!!!!

I am replying to this old post because I had the same issue and this post came up on a google search.
Hopefully it may assist someone else having the same issue and like me, is having a little panic.
The front layshaft bearing, (the lower one) is a sloppy fit in the bolt on housing on the front of a R380 gearbox, this seems wrong. However the bearing actually located by the main gearbox case and will be a tight fit there when the housing is bolted on.
So if you have noticed the same issue "DON'T PANIC", they are meant to be like that.

Rougharse Racing said:

I am replying to this old post because I had the same issue and this post came up on a google search.
Hopefully it may assist someone else having the same issue and like me, is having a little panic.
The front layshaft bearing, (the lower one) is a sloppy fit in the bolt on housing on the front of a R380 gearbox, this seems wrong. However the bearing actually located by the main gearbox case and will be a tight fit there when the housing is bolted on.
So if you have noticed the same issue "DON'T PANIC", they are meant to be like that.

Click to expand...

Plus of course when it is in use the front of the shaft is held steady in the socket in the back of the crank/flywheel, so a little movement in the input shaft bearing can be tolerated. I got a reconditioned gearbox and it was much tighter. But a well used one can appear to have an alarming amount of movement.