Land Rover Defender 90 110 Workshop Book 3 Rover

LT77 FIVE SPEED GEARBOX 13 
1. .,.. P ~ ,.- .; 
The 
latest  model  gearbox  employs a spring-loaded 
biased  gear change  lever assembly  and the following 
instructions 
(212 to 236) include  the fitting  and 
adjustment 
of this  arrangement. 
.. 
Gear  selector  housing 
212. Refit  the gear  selector  rollers, pin and  new  circlip 
ensuring  circlip is not  expanded  beyond minimum 
necessary  to obtain  entry. 
213.  Lubricate 
the gear  selector  housing shaft with 
light 
oil and fit a  new ‘0’...

E[ LT230R TRANSFER GEARBOX 
LT 230 R TRANSFER BOX 
The  following  operations  can be carried  out with  the 
gearbox 
in the  vehicle.  For ease  of working,  the vehicle 
should  be raised  on 
a ramp or placed  over a pit. Also, 
the  battery  should be disconnected for safety. 
RENEW  SPEEDOMETER  DRIVE PINION 
1. Raise the vehicle  on a ramp. 
2.  Remove  the speedomcter  drive clamp  and nut and 
3.  Prise  out 
the drive  pinion  assembly. 
4.  Push 
in a new  assembly  and fit the speedometer...

LT230R TRANSFER GEARBOX 137 I 
. _..._ _(-.-_ ,,..j .* _.. 1_...  .I 
15. Locate rear thrust  washer  (plain side uppermost) 
16.  Gently  push gear assembly 
into mesh. 
17. Using  a screwdriver  through the intermediate  shaft 
hole  guide 
thc locating  tab on the rear  thrust 
washer 
into the  slot  provided in the transfer  case. 
18. Align gear and thrust  assembly  and slide the 
intermediate  shaft into the transfer  box from the 
rear. 
19. Align the shaft so that  the lock  plate in the end is...

LT230R TRANSFER GEARBOX 
OVERHAUL LT230R TRANSFER GEARBOX 
Service tools: 
RO 605862 - Intermediate  shaft removal 
18G1273 - Sed1 remover  arm. 
18G1205 - Flange wrench 
18G257 - Circlip pliers  linkage. 
18G1422 - Oil seal  replacer 
18G1423 -Stake  nut remover 
MS47 - Hand  press 
18G47BB/1- Collars 
18G47BB/3 -Button 
18G47BB/2 - Collars 
1801424 - Differential  centre bearing  drift 
18G47-7 - Collars and buttons 
LST 47-1 - Collars 
REMOVE 
ASSEMBLIES FOR  OVERHAUL 
(Instructions 
1 to 33) 
6....

~~230~ TRANSFER GEARBOX 137 I 
GENERAL ARRANGEMENT OF LT230R TRANSFER  GEARBOX 
4 
21  

. 
LT230R TRANSFER GEARBOX 
GENERAL ARRANGEMENT  OF TRANSFER  GEARCHANGE  HOUSING 
1. Main selcctor  lever. 
2. Transfer  gear selector  assembly. 
3. Differential lock selector assembly. 
ST886M 
1 - 5 
f; 
P -* ‘J 
22  

LT230R TRANSFER GEARBOX 1371 
Transmission  brake removal 
9. Remove  the  two  countersunk  brake  drum 
10. Removc the four bolts  securing  the  brake 
retaining screws 
and 
pull off the  drum. 
backplate,  two 
of these also retain the oil catcher. 
NOTE: An hexagonal  type socket  should  be used 
for  these  bolts. 
Bottom  cover removal 
11. Hemove the ten  bolts  retaining  the bottom  cover. 
Intermediate  shaft removal 
12. Remove  the shaft  lock  plate  retained by a single 
bolt  at the...

(371 ~~230~ TRANSFER GEARBOX 
Input gear removal  30. Remove  the centre  differential  unit with  the 
selector 
shaft/fork assembly. 
19.  Remove  the two  countersunk  screws and release 
the  mainshaft  bearing housing. 
20. Remove the gasket. 
21.  Remove  the input  gear assembly. 
22.  Prise  out and  discard  the oil seal  at the  front  of the 
transfer  case using  service  tool 
1861271. 
23. Drift out the input  gear front  bearing  track. 
Highhow selector housing  removal 
24.  Remove 
the...

LT230R TRANSFER GEARBOX 1371 
Reassembling 
34. Ensure  that all faces of the transfer  box are clean. 
35. Check  that level/filler and drain  plugs  are in 
position. 
36.  Fit 
the two  studs  which  are used for part  retention 
of  the  extension housing. 
37.  Screw 
in the ‘radial’  dowel. It is important  that its 
projecting  blade is set 
radially in line with the 
tapped  fixing hole centres 
in the transfer  box 
casing.  46. 
Remove  the speedometer  driven gear and spindle 
47.  Remove  the...

(37 I LT230R TRANSFER GEARBOX 
53. Carefully charge the lips  of the  seal with  grease. 
54. Fit oil catch  ring on to  housing. 
55. Fit oil seal  into  speedometer  spindle  housing 
(open  side inwards)  with a suitable 
tubc. 
56. Fit ‘0’ ring  to speedometer  spindle housing. 
57.  Lubricate  seal and 
‘0’ ring with oil. 
58. Locate  speedometcr  driven gear and  spindle in 
spindle  housing  and push into  position. 
59. Slide speedometcr  drive gear and spacer  onto 
output  shaft. 
60. Fit...