Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

TRANSMISSION 139 
L 
 (r; 
SELECTOR RAILS AND FORKS 
21 
ST2002M 
11  

)371 TRANSMISSION 
18. Remove the two bolts securing  the fifth  gear 
fork and bracket  assembly  to the  gearbox. Do 
not  displace  the selector fork slipper pads 
when  removing  the fork. 
3. Remove  the fifth  gear,  spacer,  needle roller 
bearing  and thrust  washer. 
Reverse shaft,  mainshaft,  and layshaft. 
1. Remove  the circlip,  selective  washer, oil seal 
collar,  and 
0 ring from  the mainshaft. 
ST2006M 
2. Remove  the fifth  gear  synchromesh  hub and 
baulk  ring. 
4. Engage  both...

.- 
TRANSMISSION 
7. Remove the seven  bolts and withdraw  the 
37 
._ - front cover  and gasket. 
8. Remove the layshaft  front bearing  spacer and 
shims. 
Sr2012M 
14. Lift-out  the  layshaft  assembly. 
15. Remove  the mainshaft  assembly. 
15 14 
9. Remove the gearbox  case and stand  from the 
vice. 
10. Remove  the stand from the case. 
11. Remove  the seven  bolts that secure  the two 
halves of the case  together. 
12. Rest  the case on the  bench  with the reverse 
gear 
idler side  downwards....

1371 TRANSMISSION 
16. Remove the reverse  lever pivot bolt from  the 
17. Remove  the reverse  lever and spacer  from the 
outside of the casing. 
idler  gear and 
case. 
18. To remove  the reverse  gear idler shaft,  place 
the  case  on a block 
of timber  and with 
assistance,  hold the 
case firmly  and. drive-out 
the  shaft  using  impulse  extractor  18G 284 and 
adaptor 
LST 284-1. 
19.  Remove  the reverse 
idler gear.  and thrust 
washer. 
78G284 
gl* 
INSPECTION  AND OVERHAUL. 
Main gearbox...

-- 
TRANSMISSION 37 
-*L Bias spring  housing  and lower  gear lever 
1. Secure  the housing  in a vice  and remove  the 
2. Clean the lower gear lever  and nylon  cup. 
3. Check  the rubber  dust cover  for damage. 
4. Clean  the housing,  adjusting  screws and bias 
5. Clean  and examine  the bias  springs. 
6. Refit  the bias  spring  screws,  two turns  only at 
bias 
spring  adjusting  screws. 
Check  for wear  and damage. 
spring  bores. 
this  stage. 
4 
ST2019M 
Gearbox  fifth gear  extension...

37 
Bell housing. 
J 
TRANSMISSION 
1. Remove the clip  retaining  the thrust  bearing 
carrier  to the  clutch  operating  lever 
fork if still 
in position. 
Note:  the clip  is fitted  during  assembly  to 
prevent  the bearing  sliding forward  when 
the  gearbox  is being  fitted 
to the engine 
and  it may  become  dislodged  in 
service 
without detriment. 
2. Withdraw  the thrust  bearing  and carrier 
assembly  from the sleeve. 
3. Remove  the bolt  and spring  washer  securing 
the  operating...

TRANSMISSION 
. ... I, I. . .. , , . . . . , , .. . , . .I ./. ...... 
39 
5. Clean  all components  and ensure  that the two 
oil-ways  in the  input  shaft are clear  by blowing ST2075M 
through  with an air  line. 
9. Check,  with a feeler gauge,  the clearance 
between  the bearing  and washer. 
If the 
clearance 
is in  excess of 0,075” remove  the 
circlip  and washer  and select  and measure 
a 
new  washer to take-up the  excess  clearance. 
Continued 
L 
.^. .. . .. . 
17  

137 I TRANSMISSION 
1 
ST2029M 
10. Fit the  new  selective washer,retain with  the 
circlip  and 
recheck that the above  clearance  is 
maintained. 
11.  Lubricate  the mainshaft  pilot bearing  and fit 
to 
the mainshaft. 
12.  Fit the  fourth  gear baulk  ring to the  input 
shaft. 
13. Fit  the  snap  ring to the  bearing. 
4. invert  the mainshaft  assembly,  in the  vice,  and 
remove  the mainshaft  rear bearing  circlip. 
IL ST2076M 
Mainshaft 
1. Secure the mainshaft  assembly in a vice and...

.. . it: ,;  ... ! ... 
TRANSMISSION 37 
5. Using press MS 47, and a support  under the 
first  gear,  press  the mainshaft  assembly from 7. In addition  remove the remaining  items:- 
the rear  bearing. 
ST2032M 
6. Separate  the following  components  from the 
assembly:
- 
A. First  gear. 
B. First  gear  bush. 
C. Spacer. 
D. needle roller. 
E. Selective  washer. 
F.  Rear  bearing  snap ring. 
A. First gear  baulk  ring. 
B. First and second  synchromesh. 
C. Second gear baulk  ring. 
D. Second...

37 
FirstJsecond synchromesh assembly. 
TRANSMISSION 
1. Before dismantling,  mark the relationship of 
the synchromesh  hub to the  sleeve. 
2. Fit the  baulk  rings to the  synchro- mesh 
assemblies  to facilitate  dismantling  and to 
prevent  damage 
to the springs. 
3. Place  the synchromesh  assembly in a clear 
plastic  bag, 
to prevent  the components  being 
lost  and whilst 
in the bag, press  the sleeve 
from  the hub. 
IJ 
2 1 
ST2035M 3 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
Retrieve  the...