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 first and fourth  gears to lock the 
gearbox.  Release the stake  nut collar  from the 
recess  in the  layshaft  and remove  the nut and 
fifth  gear. 
-\. 
:-& 
,- E: I/ 
5. Fit the  manufactured  spacer to the  layshaft  to 
keep  the rear  bearing  in position  and retain 
with  the stake  nut, finger-tight  only. Disengage 
the  first  and fourth  gears. 
6. Remove  the two socket-headed set screws 
and 
two bolts  and remove  the plate  that 
retains  the layshaft  bearing  track and reverse 
shaft. 
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							.- 
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. 
13. Carefully  separate the case  by tapping  with a 
hide  mallet  alternately  at the 
four corners,to 
break  the seal. 
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							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 case 
Note:  The following  instructions 1 to 4 are only 
necessary 
if the  gear  casings, plugs or 
dowels  are being  renewed. 
1. Remove  the drain  plug. 
2. Remove  the fillerilevel plug. 
3. Remove the interlock  cross drilling plug 
4. Remove  the six hollow dowels. 
Front  cover. 
1. Place the front  cover  on a block of timber  and 
drift
-out  the oil seal. 
2. Clean  the cover  and check for damage  or 
burrs. 
3. Lubricate  the outer  diameter of a new  seal and 
using  a suitable  tube, drift
-in the  seal,  lip side 
trailing,  squarely  into the cover. 
Continued 
.:a. .i .::! ..:d e ;.- 
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							-- 
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  housing. 
1. Remove the rear oil seal  from  the extension 
housing  using a suitable  drift. 
2. If necessary,  renew the extension  housing 
dowels. 
3. Clean  the the exterior  and interior  and the 
mating  faces. 
4. Using service tool LST 102 fit a new  seal to 
the  extension  housing. 
3 
5 
4 
Top cover 
I. Clean top Cover gasket faces and the interior 
2. Remove the top  filler  plug,  clean,  apply sealant 
3. Clean  the gear  lever  housing  and check  for 
and 
exterior  surfaces. 
and  refit. 
cracks  and wear. 
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							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  lever pivot  clip to the 
lever. 
4. Remove  the operating lever and  pivot  slotted 
washer. 
5. Remove  the operating  lever pivot. 
6. Unscrew  the single- bolt  and remove  the 
bearing  sleeve from the bell  housing. 
Input shaft 
1. Remove  the fourth  gear baulk  ring and needle 
roller bearing. 
7. If necessary,  remove the bearing  sleeve 
8. Clean the bell  housing  exterior and interior 
9. Apply  grease to the lever  pivot  and inner 
10. Reassemble  the bell housing in the  reverse 
dowels. 
and  mating  faces. 
diameter 
of bearing  carrier. 
order 
of dismantling. 
ST2023M 
2. Remove  the circlip  and selective  thrust washer. 
3. Remove  the snap  ring from  the bearing. C--%l -. Y 
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							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 
remove  the circlip  retaining  the 
third/fourth 
synchromech  hub and gear  assembly. 
2. Remove  the selective  washer, third/fourth 
synchromesh  assembly and baulk  ring. 
3. Remove  the third  gear,  spacer,  and needle 
roller  bearing. 
I I 
Continued 
18  
						

							.. . 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  gear spacer. 
E. Second  gear needle  roller bearing. 
F. Second  gear. 
A 
sT2034 M 
8. Clean the mainshaft  and all components  and 
examine 
for obvious  wear. 
ST2033M 
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							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 synchromesh  balls, springs  and 
slipper  pads and remove  the baulk  ring. 
Clean  all the  synchromesh  assembly 
components.  Before  reassembling  the synchromesh  units 
carry  out the checks 
for third  and second  gear 
end  floats  as described  under the heading 
Mainshaft  and gear  train clearance  checks. 
Fit  the  synchromesh  hub 
to the sleeve 
ensuring  that the alignment  marks line
-up. 
Place  the hub  and sleeve  on a 
level block. 
With  the hub  resting on the block  adjust  the 
height 
of the  hub  sufficiently  to fit the  springs. 
Locate the slipper pads,fit the  springs  and 
press  the balls  down  to be  retained  by the 
synchromesh  sleeve. 
Fit  the  baulk  ring 
to the hub  and sleeve. 
ST1477M 10 
12. 
13. 
14. 
Carefully  invert the synchromesh  assembly and 
fit  the  second  baulk ring. 
Press  the synchromesh  sleeve over the hub  to 
locate the balls  in position. 
Remove  the baulk  rings. .. x - 
Thirdtfourth  synchromesh  assembly. 
1. 
2. 
Repeat the instructions as for the first/second 
synchromesh  assembly but omit  the gear 
end
-float  checks. 
when  reassembling  the synchromesh  unit, 
ensure  that the large  chamfer  on the  sleeve 
faces  the small  boss on the  hub. 
Fifth  gear sychromesh  assembly. 
g-?: 1. Repeat the instructions  relating to the f, ,, 
firstlsecond synchromesh  assembly. 
2. Note that when  reassembling  the fifth  gear 
synchromesh,the chamfer  on the  hub,  faces to 
the rear. 
20