I am overhauling the 380J gearbox of my 1994 Defender 130 tdi. I replaced all bearings so far. When I pressed them back in I was pressing them very firm but did not overdo it since i was concerned that some gears might bind up.
Over the last few days I started to put it together. Shims are set correctly and once I put the reverse gear and the selector back in (I used the original shim / washer which goes first), it supposed to get set with an o-ring. However whatever I try it seems like it is about 1mm out and I cant get the o-ring set correctly.
I checked online if I can change the shim, but it seems only sizes from about 2mm to 3mm are available. The one which is in place is 2.2mm.




So I wonder if there is an option to get a thinner shim or, did I make a mistake when pressed the bearings in and should press them a bit tighter and make up the 1mm gap? Or is there another trick to get this done?

Any input would be highly appreciated.

 

Personally, l'd start over and disassemble it to the point of removing everything on that shaft. Obviously, if you need a 1mm shim...and they don't make a 1mm shim...it is not designed to use a 1mm shim.

My workshop manual is for 1983 - 1995 and only shows LT77 and LT85 breakdown of transmissions.

 

Thanks for the reply. As you mentioned, I decided to start over. Unfortunately I had to destroy the brand new bearing to get it off and had to wait for a new one. I assembled the the gear box only after almost 6 months I took it apart, since I was moving houses. I realized that one of the synchro rings was missing which I found in the pile of the gears I put in a box. I used the removed bearings, ground them out so I could slide them easily on and off. Before I took everything back together I checked if the o-ring would fit and this time it looks like it is spot on. Should have paid more attention and double checked before pressing the bearings in.