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’ ring. 
214.  Insert  shaft  through the large  blanking  plug 
orifice,  ensuring  the shaft  indent  is uppermost. 
215.  Place  the gear  selector  housing into protected  vice 
jaws  and fit the  selector  yoke to the  shaft,  using a 
suitable  pin punch  and new 
roll pin.  Remove  the 
housing  assembly  from the vice  on completion. 
216.  Fit the  reverse  switch and large  blanking  plugs. 
Coal  plug threads  with Loctitc  290 and  tighten  to 
217.  Refit  the 
fifth gear spool retainer  and tighten  the 
bolts  and washer  7 
Nm (5 Ibf ft) and fit a new 
nylon insert into the trunnion  housing and secure 
with  a 
new circlip. 
218.  Invert  the gear  selector  housing and 
fit the 
trunnion  housing to the  sclector 
shart, ensuring 
the  locating  bolt  aligns  with the shaft  indent.  Coat 
the  bolt  threads  with Loctite 
290. Tighten  bolt to 
the  specified  torque. 
219.  Fit a new  gear  lever  gasket  and locate  the gear 
lever housing,  spring washers  and bolts.  Tighten 
bolts 
to the  specified  torque. 
220.  Fit the  two  bias  spring  adjustment  screws and lock 
nuts. 
221.  Place  the bias  spring  in position  with the spring 
legs  either  side of the  gear  lever  housing  and 
retain  with a roll
-pin. 
222.  Coat  the upper  and lower  spheres 
of the gear 
lever  shaft with 
Duckhams Q.5848 or Shell 
Alvania RI and  locate  the lever in the gearbox 
and  retain  with the bolt  and special  lock washer. 
223.  Using  a screw  driver  lift the  bias  spring  legs over 
the  gear  lever  crosspins. 
Do not overstress  the 
spring  legs. 
Refit the main  gear lever with the 
gaiter.  Align the marks  made when dismantling. 
Tightcn the 10 mm ‘Nyloc’ nut. 
224. Select  first or second  gear. It may  bc necessary  to 
rotate  the mainshaft  whilst manipulating  the gear 
lever. 
225. Locate  the reverse  gear plunger  assembly  on the 
right  hand  side viewed  from rear, giving  sufficient 
load 
on the  trunnion to eliminate  side play.  Whilst 
maintaining  a light 
finger pressure,  measure the 
and  gear  selector  casting. Add 0,6 
nim’to the 
measured  figure and select  suitable  thickness 
shims  to equal  the total. 
226.  Remove  the reverse  plunger  assembly, 
fit the 
required  thickness 
shim(s) and refit  the plunger 
assembly,  spring washers  and bolts.  Tighten  to the 
specified  torque. 
-  ~ the 
specified  torque. 
c!e2!2r?ce between the p!unger assemb!y casting  227. 
Fit the 
fifth gear  stop on the left hand  side viewed 
from  the rear,  giving  sufficient  load 
on the 
trunnion  to eliminate  side play.  Whilst 
maintaining  a light  finger  pressure,  measure the 
clearance  between 
the plunger assembly  casting 
and  gear  selector  casting. Add 
0,6 mm to the 
measured 
figurc and  select  suitable  thickness 
shims  to equal 
the total. 
228.  Remove  the fifth  gear  stop, 
fit the required 
thickness 
shim(s). Refit  the gear  stop assembly, 
spring  washers  and bolts.  Tighten 
bolts to the 
specified  torque. 
229. 
To adjust  the bias  springs  with the unit  completely 
assembled,  engage either third 
or fourth  gear. 
230.  Adjust  the two  adjusting  screws 
until both legs of 
the spring  are approximately 0,5 mm clear  of the 
cross
-pin in the  gear  lever.  This should  allow a 
certain  amount of radial movcmcnt of the gear 
lever  without  the cross
-pin  contacting  either of thc 
spring  legs. 
231.  Apply  a slight  load to 
the gear  lever  knob in a left 
hand 
dircction to position  the gear  lever  at one 
extreme 
of the  radial  play. Adjust  the right  hand 
adjusting  screw downwards 
until the right  hand 
spring 
Icg just  makes  contact  with the cross-pin on 
the  right  hand  side. 
232.  Repeat  instruction  229 
in the opposite  direction. 
233.  At this  stage,  radial play will still be present,  but 
at  the  other  extreme  the cross
-pin should  just 
make  contact  with the spring  leg on the  other  side. 
234. r IruwcI _..._.. 50th adjustiiig screws equal ~m~iiiii~ iiiitil 
the radial  play is just  eliminated.  Tighten 
lockn 
u ts. 
235.  Return  gear lever  to neutral  position  and rock 
across  the gate  several  times. The gear  lever 
should  return 
to the third  and fourth  gate. If not, 
repeat  the 
aforcmentioned procedure. 
236. 
Fit the  rubber  gaiter and secure  with a strap. 17  
						

							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 
withdraw 
the cable. 
cable  and secure  with the clamp  and nut. 
RENEW  REAR OUTPUT  SHAFT OIL SEAL 
Special  tool: 
18G1422 
1. Disconnect  the battery  for safety. 
2.  Disconnect  the rear  propshaft  from 
the output 
3. Remove thc brake drum retaining  screws and 
4.  Remove  the two  back  plate  bolts that also  retain 
flange. 
withdraw  the drum. 
thc oil catcher  and remove  the catcher. 
NOTE:  An hexagonal  type socket  should  be used  for 
these  bolts. 
5. Remove  the output  shaft nut and  washer  and 
6. Using thc slot provided,  lever off the  dust  cover. 
7.  Prise  out the output  shaft oil 
seal(s). 
8. Using  special  tool 1861422 fit the doublc-lipped  oil 
seal,  open  side inwards,  with the seal  in contact 
with 
the bearing  circlip, taking care not to touch 
the  seal  lips. 
withdraw 
the flange. 
NOTE:  The double-lipped  oil seal  supersedes  the 
two 
oil seals  used on early  production. 
9. Fit  the  dust  cover. 
10. Lubricate  the surface  of the  flange  which runs in 
the seal  and carefully  fit the  flange. 
NOTE:  To renew  the flange  bolts first remove  the 
circlip  before fitting the flange. 
11.  Secure  the flange  with the nut  and  washer  and 
tighten  to 146  to 
179 Nm (108 to 132 Ib ft). 
rubber  sealant  and secure  with the two  back  plate 
bolts  (with  plain washers). 
13. 
Fit the  brake  drum and retain  with the two  screws. 
14. Reconnect the propeller  shaft. 
12. Fit oii catchei to the “u& using si~icoiie 
RENEW FRONT OUTPUT  SHAFT OIL SEAL 
Special  tool: 
18G1422 
1. Disconnect  the front  propeller  shaft from the 
flange  and move  to one  side. 
2.  Remove  the output  shaft nut and  washer  and 
withdraw  the flange. 
3.  Remove  the oil seal  shield. 
4. Prise  out the oil seal(s). 
NOTE:  The double-lipped oil seal supersedes  the 
two 
oil seals  used on early  production. 
5. Using  special oil seal replacer  tool 1863422 fit the 
double
-lipped oil seal,  open  side inwards,  with the 
seal  in contact  with 
the bearing  circlip, taking care 
not  to touch  the scal  lip. 
6. Lubricate  the running  surface of the flange and fit 
it together  with the oil seal  shield. 
7. Secure the flange  with the nut and  washer  and 
tighten  to 146  to 179 
Nm (108 to 132 Ib ft). 
S. Refit the propeller  shaft. 
W 
REMOVE  INTERMEDIATE  SHAFT AND GEARS 
Service  tool: 
R0605862 
1. Drain the transfer  gearbox oil. 
2. Disconnect the rear propshaft from the output 
flange. 
3.  Remove  the two  screws  and withdraw 
the brake 
drum. 
4.  Remove  the four  bolts  securing  the brake  back 
plate  and withdraw  the back  plate  and oil catcher. 
NOTE: An hexagonal  type socket  should  be used  for 
these  bolts. 
g-2 
5. Remove  the intcrmediatc shaft keeper  plate, -.- 
retained  by a single  bolt. 
6. Remove  the ten  bolts  and remove  the bottom  cover 
plate. 
7. Using  service  tool R0605862 withdraw the 
intermediate  shaft whilst  holding  the gear  cluster. 
Collect  the bearings  and thrust  washers  from both 
ends  of the  cluster. 
8. Remove  the two ‘0’ rings,  one from the shaft,  the 
other  from the casing. 
Fit intermediate  shaft gears 
i0. Fit the -0‘ ring into the front of the transfer  case. 
11. Lubricate  thrust washers,  bearings,  shaft and 
12.  Fit needle  bearings  with spacer  interposed. 
13.  Fit front  thrust  washer  to slot 
in transfer  case (plain 
14. Locate  gear assembly  partially into the transfer 
9. 
Fit the ‘0’ ring 
to thc intermediate  shaft. 
spacer. 
6.’. side  to case).  N’ 
case so that it rests on the  front  thrust  washer. 
18  
						

							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 
on top. 
20.  Apply  Loctite 
290 to the  lock  plate  bolt threads. 
Locate  lock plate  into position  and 
fit securing  bolt 
(with  spring  washer). 
21.  Lever  the 
gear.assembly to one  side  and measure 
the  end
-float with feeler  gauges.  This should  be 
between 
0,08 and 0,35 mm (0.003  and 0.014  in). 
22.  Grease  and 
fit the bottom  cover joint washer. 
23.  Apply  Loctite  290 to the  ten 
bolts and  evenly  ~ 
tighten to 22 to 28 Nm (16 
to 21 Ibf ft). 
24, 
Fit the  oil catcher  to the  brake  plate, using silicone 
rubber  sealant  and secure  the backplate  with the 
four  bolts.  The 
two bolts securing  the oil catcher 
are  fitted 
with plain  washers. 
25. Fit the  brake  drum and retain  with the two  screws. 
26.  Connect  the rear  prop  shaft. 
27. Refill the transfer  box with  the correct  oil. 
into 
slot in transfer 
case. 
T . ..  ... .. .. :., ,. 
. :. , : L.: ,. .... . ... . I .. 
19  
						

							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. Disconnect  the bottom of the high/low connecting 
rod  from  the 
high/low operating  arm by removing 
the  split  pin and  clevis  pin. 
7. Remove  the plastic  bushes  from the operating 
8. Remove  the gearchange  housing complete with 
8 
1. Having  removed  the complete  gearbox and 
transfer  box assembly.  The transfer  box 
is 
separated  from the gearbox  on the  work  bench. 
NOTE:  To facilitate  removal of various  items on 
the  work  bench,  obtain suitable  wooden blocks to 
enable  the transfer  box 
to be turned  and propped 
up 
as required. 
Hand  brake  linkage  removal 
2. Remove  the split  pin and  clevis  pin to release  the 
handbrake  linkage from the brake  operating 
lever. 
3. Remove  the two  bolts  (with  spring  washers) 
securing 
the rear  end of the handbrake  mounting 
bracket 
to the  casing,  the lower  bolt is shorter. 
4. Remove  the two  bolts  (with  spring  washers  and 
distance  pieces) securing  the front  sidc 
of the 
handbrake  mounting bracket and remove  from 
the  transfer  box. 
Transfer 
box mounting  removal 
5. Remove the bolts  retaining  the right  hand  rubber 
mounting  plate. 
20  
						

							~~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  rear  face of the transfer  box. 
13. Withdraw the intermediate  shaft,  using a screw 
driver  in 
the slotted  end. Where  the shaft  cannot 
be  easily  withdrawn use extractor 
R0605862. 
14. Lift  out  the  intermediate  gear  cluster, roller 
15. Remove the thrust washers. 
16. Remove  the 0 ring from  the intermediate  shaft 
and  the transfer  box case. 
bearings 
and spacer. ST 1 
Power take off cover  removal 
17. Remove  the  four bolts  retaining  the circular 
P.T.O. cover  and the speedometer  cable clip 
plate. 
18. Removc  the gasket. 
NOTE:  The other  two bolts  were removed  with the 
gearbox  assembly  cradle.  
						

							(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 six  bolts to release  the selector 
25.  Remove  the gasket. 
housing. 
Front  output  shaft housing  removal 
26.  Slacken  the square  headed  set screw  securing  the 
yoke to the high/low selector  shaft inside the 
highhow selector  housing  aperture. 
27. If necessary  use a screw driver to move the 
selector  shaft rearwards  and allow 
thc yoke to be 
lifted  out. 
28.  Remove  the eight  bolts 
to release  the front  output 
shaft  housing  assembly. 
The upper middle  bolt is 
longer. 
NOTE: The  ‘radial’  dowel in the  transfer  box face 
should  not be disturbed. 
Centre  differential  removal 
29.  Remove  the 
high/low selector shaft detent  plug, 
spring  and ball. 
NOTE:  The ball may  be more  easily  retrieved  from 
inside  the transfer  case after  the selector  shaft is 
taken  out. 
24 
ST1165M 
4z-L rl. Rear output  shaft housing  assembly  removal *:a. ..bi’ 31. Remove the six screws to relcase the  housing.  The 
32.  Remove  the gasket. 
upper 
screw is longer. 
NOTE:  Removal  of the  above  housing  will reveal 
the  centre  differential  rear bearing  track in the 
transfer  box casing.  Before drifting  out, either 
unscrew  the two  studs  and radial  dowel projecting 
from  the transfer  box front  face or use  suitable 
wooden  blocks to support  the box 
to avoid  damage 
to  these  items. 
33. Drift out the differential  rear bearing  track. 
NOTE:  If it is  required  to completely  strip down 
the  transfer  box to the  basic  casting,  remove the 
level,  filler and drain  plugs. 
IMPORTANT:  Clean all parts  ensuring  any traces 
of  Loctite  are removed  from faces and threads. 
Ensure  that the magnetic  drain plug 
is thoroughly 
cleaned.  Renew 
oil seals and examine  all other 
parts  for wear 
or damage, renew  as necessary. 
f-, --.  
						

							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 
‘0’ ring and oil seal. 
from 
the spindle  housing. 
n 
Rear output  shaft housing - Overhaul  (Instructions 47 
to 73) 
Dismantling 
38. Using flange  wrench 1861205 remove  the flange 
nut. steel  and felt washers. 
NOTE:  Ensure flange bolts are fully  engaged  in the 
wrench. 
h 38 48.  Slide  off the  spacer  and speedometer  drive gear 
from  the output  shaft. 
49.  Clean 
all parts,  renew oil seals and Nyloc  flange 
nut  and  examine  all 
other parts for wear or 
damage,  renew as necessary. 
Reassembling 
50. Press the output  bearing  into the housing.  Do not 
use  excessive  force. If necessary  warm the housing 
and  case. 
51. Fit the bearing  retaining  circlip using circlip  pliers 
186257. 
52. 
Fit a new  dual  lip oil  seal (open  side inward),  with 
the  seal  in contact  with the bearing  circlip 
it is 
essential  to use  replacer  tool 1861422. 
NOTE:  On early  production  two separate  seals 
were  used,  these 
should be replaced  with the new 
dual  lip seal. 
39.  Remove  the output  shaft flange  with circlip 
attached.  If necessary,  use a two
-legged  puller. 
NOTE:  The circlip  need only be released  if the 
flange  bolts are to be  renewed. 
40.  Remove  the speedometer  spindle housing.  This 
can  be prised  out with 
a screw  driver. 
41.  Remove  assembly  from vice and support  the 
housing  to allow  removal 
of the shaft,  drifting it 
out by striking  the flange  end of the shaft. 
driver 
in the slot provided. 
18G 1271. 
retaining  the bearing. 
housing. 00 52 
42. CarefL!!!y prise nff the oi! catch ring llsing 2 screw 
43.  Prise  out and  discard  the seal(s) using tool 
44.  Using  circlip  pliers 
18G257 remove  the circlip 
45.  Drift  out the bearing  from the back  of 
the ST903 M 
25  
						

							(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 output  shaft  to the  bearing in the rear  output 
shaft  housing. 
61. Examine the flange  seal  track  to check  for  any 
damage that  may harm  the seal. Retain  for fitting 
later. 
62. Locate  speedometer  spindle housing  assembly in 
the output  shaft  housing  and  push  in flush with 
housing face. 
-NOTE: Before  fitting the rear  output  shaft housing 
to  the  transfer  box casing  the  centre  differential 
rear  bearing  track must be fitted. 
63.  Drift  the centre  differential  rear bcaring track into 
the  transfer  box casing 
1,5 mm (:,; in) below  the 
outer  face of the  casing.  Check the depth  before 
proceeding. 
Fitting  rear output  shaft housing  to transfer  box 
64. Grease  and fit housing  gasket  and locate  the 
housing 
in position on the  transfer  box. 
NOTE: If the  differential  rear main  bearing  track 
has  been  correctly  fitted there will be a gap 
between  the housing  face and the gasket  at this 
stage. 
65. Apply Loctite  290 to the threads of the six housing 
securing  screws,  noting  that the upper  screw is 
longer. 
Fit the  screws  (with spring  washcrs) 
evenly  tightening  them to the  specified  torquc. 
This  will press 
in thc rear  main  bearing  track to 
the  correct  position  and seat 
thc housi3g. 
Centre  differential  Unit - Overhaul 
(Instructions 
66 to 119) 
Dismantling 
66. Detach the high/low selector  shaft and fork. 
ST1189M I1 I I II I 
67. Using  soft jaws  secure  the differential  unit in a vice 
with the ‘stake’ nut  uppermost. 
68. Remove the peened-ovcr metal to facilitatc 
removal of the nut. 
69. Remove  the ‘stake’  nut using tool 18G1423. 
70. Remove  the differential  unit from  the vice. 
71. Secure  hand press MS47 in vice with  collars 
18G47BB/1 and using  button 18G47BB/3 remove 
rear taper (twenty
-four)  roller  bearing  and collars 
LST 
47-1 for  latest  (twenty-three) roller  bearing. 
72.  Substituting  collars 
18G47BW2 remove  front 
taper  roller  bearing. 
73. 
Remove  the hand  press  from the vice. 
STl166M ii i 
74.  Remove  the  high range  (smallest)  differential f=:. gear and its bush. ’ d 75.  Mark  the relationship of the highhow selector 
sleeve 
to the  hub  and remove the  sleeve. 
26