Land Rover Defender 90 110 Workshop Book 3 Rover

LT85 FIVE SPEED GEARBOX 
I 1 I l. GEARBOX DATA 
- 
37 
Mainshaft first speed  gear running  clearance 
Mainshaft  third 
spccd gcar running  clearance 
Mainshaft 
fifth speed  gear running  clearancc 
Input  shaft bearing  running 
clcarance 
0,075 mm maximum 
0,075 
mm maximum 
0,075 mm maximum 
0,075 
mm maximum 
DISMANTLING Bias spring housing  and gear  lever 
1. Ensurc gearbox oil has bcen completely  drained. 
2. Position gearbox on bench and support with 
3. Remove  four bolts  and detach L.H....

17 LT85 FIVE SPEED GEARBOX 
Selector rails and forks 
19. Using a suitable magnet withdraw  the selector  rail 
detent  balls from  drillings 
in gearbox. If detent 
balls arc tight leave  operation until after selector 
rails  have  been  withdrawn, 
when the detcnt  balls 
can  be pushed  down into the selector  rail 
borc, 
then removed. 
20. Release  reverse gate spring  from knock-over lever 
and  remove  from reverse  gear rail. 
21. Raise  knock-over lever  and tap down  reverse  jaw 
roll
-pin...

LT85 FIVE SPEED GEARBOX 
,: ..: ,. z..:. -... .. 27. Tap  down 3rd/4th jaw roll pin until jaw is free on : ;$ .._ji  selector  rail. .:: .-,. 
28. Withdraw 3rd/4th selector  rail and  jaw. 
20. Remove  interlock  from 3rd/4th sclcctor rail. 
30.  Tap  down 
lst/2nd jaw roll pin until .jaw is free  on 
sclector  rail. 
31. Remove  clamp bolt from Isti2nd selector fork and 
withdraw 
lst/2nd selector  rail and jaw. 
32.  Remove  interlock  from lst/2nd sclcctor rail. 
33.  Lift  rcverse  cross
-over lcvcr...

E[ LT85 FIVE SPEED GEARBOX 
40 
40. Remove  mainshaft  rear bearing  circlip. 
41. Release  stake nut collar  from recess in layshaft, 
remove  stake nut and  5th gear  from  layshaft. 
NOTE: To facilitate  this  operation lock gearbox  by 
engaging  both 
1st and 4th gears. 
ST1332M e 
41 
42. Fit manufactured  spaccr to layshaft to retain  rear 
bearing  and secure 
in position with stake  nut 
finger
-tight  only 
42 ST 
43. Disengage  1st and  4th gears. 0 7..::. 
44. Remove two socket hcad set...

LT85 FIVE SPEED GEARBOX I37 I 
49. Remove  layshaft front bearing  spacer. 
50.  Remove  input shaft bearing  circlip and selective 
51.  Remove  bolts and spacers  retaining  front bcaring 
washer. 
plate 
to gearbox. 
56 
57 
ST1336M 
50 
58. Extract  mainshaft from rear bearing. To facilitate 
operation  assistance  will be needed 
to support 
mainshaft  and layshaft. 
59.  Tap  layshaft  forwards  and remove  rear bearing 
race. 
60. Withdraw  mainshaft and layshaft  assemblies. 
61. Remove  rcvcrsc...

37 LT85 FIVE SPEED GEARBOX 
7. Position gearbox on suitable  wooden  blocks and 
remove  mainshaft  rear bearing  using 
Tool Nos. 
LST 550-3 and MS 550. 
7 
8. Remove  rear bearing  circlip and clcan. 
9. Using Tool Nos. LST 550-2 and MS 550 remove 
layshaft  rear bearing  outer track. 
NOTE: Use rounded  end of tool. 
10. CIea 
STl34 1 M 
earbox case asket faces, in erior and  12. 
Clean  mainshaft  and layshaft  bearing seatings. 
13. Clean rcverse  gear idler  shaft  seating,  drain plug, 
14. Using...

. 
LT85 FIVE SPEED GEARBOX 37 
Front bearing plate 
1. Support front bearing  plate on suitable  wooden 
2. Using Tool Nos. LSI 550-3 and MS 550 remove 
blocks 
as shown. 
input  shaft bearing. 
9. Using Tool No. 550-1 fit layshaft  bearing,  with 
6,5-7 mm of bearing  protruding  from front  of 
bearing  plate. This allows  easier assembly 
of the 
layshaft  and mainshaft  at a later  stage. 
2 
ST1344M 
9 
ST1347M 
10. Fit circlip  to input  shaft bearing. 
11. With  the front  bearing  plate still...

37 
Front cover and oil pump 
1. Remove  cover plate,  drive gear and impellor  gear. 
2. Remove  cover plate ‘0’ ring. 
3. Position  wooden blocks under front cover  and 
remove  oil feed  ring and 
oil seal. 
LT85 FIVE SPEED GEARBOX 
W 
ST1348M 
4. Clean  all front  cover  componcnts. 
5. Lubricate  lip of new oil seal and position in front 
6. Fully  seat oil seal in position  using suitable  tube. 
7. Fit oil feed  ring,  ensuring  the three  holes of the 
feed ring are at the  bottom  and the ccntrc...

LT85 FIVE SPEED GEARBOX 1371 
f. I... . s, Bell housing ;.:?:,*i _!.. .,, . .  . 7, 1. Remove clip retaining  thrust bearing  carrier to 
2.  Withdraw  thrust bearing  and carrier  assembly  from 
3.  Remove  bolt and spring  washer  securing  operating 
4.  Remove  operating  lever and pivot  slotted  washer. 
5. Remove  operating  lever pivot. 
6. Unscrew  single bolt and remove  bearing sleeve 
clutch 
opcrating lever fork. 
sleeve. 
lever  pivot  clip 
to lever.  Remove  pivot clip. 
from  bell...

b 
37 
3rdl4th synchro assembly 
1. Repeat operation  as for IstRnd synchro assembly 
(omitting  the 
gear end float  checks). 
LT85 FIVE SPEED GEARBOX 
NOTE: When  reassembling 3rd/4th synchro  the 
large chamfer 
on synchro slceve faces the  small boss 
on the hub, 
5th  gear synchro  assembly 
I. Repeat operation  as for Ist/2nd synchro assembly. 
NOTE: When 
chamfer on  the reassembling 
5th  gear synchro the 
hub faces to  the rear. 
Mainshaft and gear train 
3rd  gear end  float 
1. Locatc the main...