Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							TRANSMISSION I37 
I 
- -. Mainshaft and gears  clearance  checks. 
Running  clearances 9.  7 
Mainshaft  1st gear 
Mainshaft  3rd gear 
Mainshaft  5th  gear 
Input shaft bearing 
0,075 maximum 
0,075 maximum 
0,075 maximum 
0,075 maximum 
Third  gear end-float. 
1. Locate  the mainshaft  in a vertical  position as 
shown.  Fit the  third gear,needle roller bearing 
and  spacer  to the  mainshaft  and  replace the 
third/fourth synchromesh  inner member.Press 
down  on the synchromesh  inner member  and 
check  the gear  running  clearance  with  a feeler 
gauge.A clearance  in excess of 0,19mm 
(0.008ins.) indicates  that the thrust  faces are 
worn  and  may be the  cause 
of gear  noise  or 
transmission  back
-lash. New or little worn 
components 
will usually  have  a  clearance of 
between 0,075 and 0,125 (0.003in to 
0.005in) 
T 
Second  gear end float 
2. Invert  the mainshaft for assembly of the rear 
end  components. 
3.  Fit  the  second  gear  needle 
roller bearing, 
spacer,  Second  gear and synchromesh  inner 
member.  Press down  on the  synchromesh 
inner  member  and check  the second  gear end 
float  which 
is the same as the third  gear 
previously  described. 
/ ST2036M I I 
4. Remove the synchromesh  inner member  and 
assemble 
it to  the  outer  member  with the 
slippers,  balls and  springs. 
5.  Fit the second  gear baulk  ring to the  mainshaft 
and  the first  and second  synchromesh  hub 
with  the selector  groove towards  the rear  end 
of the shaft.See items I1 to 17 mainshaft 
gears,illustration ST2071M page 6. 
Firstugear to bush end-float. 
6. To carry-out  the  first  gear  check,  do not 
assemble  the  components  to the  mainshaft. 
Assemble  the spacer,  needle bearing  and bush 
to  the  first  gear  and using  a  suitable  straight 
edge 
or flat  plate,  check  the  end float of the 
first  gear  on the  bush, 
as shown.The tolerance 
is  the  same 
as for the  third  and second  gears. 
ST2037M 
21  
						

							37 
FirsUsecond synchromesh end float. 
- 
TRANSMISSION 
7. 
Sl 
Assemble,  to the  first  gear,  the spacer,  needle 
roller  bearing  and first  gear  bush  and fit the 
assembly 
to the  mainshaft.  Fit the  original 
selective  washer and dummy  mainshaft  rear 
bearing 
LST 101 and  retain  with the circlip. 
With  a 
feeler gauge,  check the end-float  as 
shown.Choose a suitable  selective  washer to 
obtain 
a minimum  clearance 
(0.003ins.) 
of 0,075 
-2038~ 
8. Remove the dummy  bearing and fit the 
9. Start  the mainshaft  rear bearing  squarely  on 
selective washer. 
the  mainshaft  then, 
9 
ST2039M 
without inverting  the shaft,  use either  a press, 
capable 
of accomodating  the complete 
mainshaft 
assembly,or drive  the bearing  into 
position  using a suitable  tube. Secure  the 
assembly  with the circlip. 
Fifth  gear end
-float. 
10. Fit the  fifth  gear  thrust  washer  with the scallop 
side  towards  the gear.  Fit the  fifth 
gear,needle 
bearing  and spacer  followed  by the 
synchromesh  assembly, 
less the baulk  ring at 
this  stage.  Press down  on the  synchromesh 
inner  member  and check  the gear  end float, 
as 
shown,  between  the gear  and thrust  washer. 
The  tolerance 
is the same as that for the third 
gear  end float. 
ST2040M / I 
Third-  fourth  synchromesh  end float. 
11. Invert the mainshaft  to a vertical position,as 
shown.  Fit the  third  gear needle  roller bearing, 
spacer,  third 
gear,baulk ring and synchromesh 
with  the larger  thrust  face towards  third gear 
and  the chamfer  on the  outer  member 
towards  the 
front.Fit the original  selective 
washer  and retain  with the circlip. 
%? %, .: -4 
Continued 
22  
						

							TRANSMISSION 
12. Check the clearance  between the washer  and 
the  synchromesh  hub. the clearance 
must not 
exceed 
0,075 (0.003ins). The  condition is 
ideal  when  the selective  washer can be just 
turned  by hand. 
37 
Reverse  idler  gear, shaft and lever. 
1. Secure the reverse  gear in a vice  and remove 
one 
of the two circlips  retaining.  the bearings. 
ST1359M 
c) 4 
ST2042M 
4. If necessary,  remove the split pin and 
withdraw  the slipper  pads and washer 
from the 
reverse  gear 
lever. 
5. Press-out the reverse lever cross  link pin, if 
necessary. 
5 
ST2043M 4 
2. Remove  the upper  thrust washer, two needle 
roller bearings  and lower  thrust  washer. 
3. Invert the reverse  gear and remove  the second 
circlip. 
23  
						

							El TRANSMISSION 
Fifth gear  selector fork and bracket. 
1. Remove  the slipper  pads from  the selector 
2. If necessary,  remove the circlips  and withdraw 
3. Clean  all components  and refit  or renew  in 
fork and check for wear. 
the  pivot  pins. 
reverse  order. 
2 A 
Lays haf t. 
4. Clean the layshaft  and bearings  and check  for 
wear,  pitting  and scores. 
5. Fit the rear bearing  assembly  and note  that the 
inner  track must 
be fitted with the 
identification  numbers facing inwards  towards 
the  layshaft  first gear. 
6. Fit the  track  and outer  bearing  with the 
identification  numbers facing outwards 
towards  the fifth  gear. 
6 
ST2046M 
7. Fit the  dummy  spacer and stake  nut loosely to 
retain  the bearing  assembly  in position  on the 
shaft. 
8. Fit  the  front  bearing  inner track with the 
shoulder  towards the gear.  carefully  tap  the 
track  squarely  into position  with 
a hide mallet. 
1. Remove  the stake  nut and  spacer  and 
2. Remove  the layshaft  front bearing. 
3. Secure  the iayshaft in a  vice  and lever-off the 
withdraw 
the complete  rear bearing. 9. Fit the  front  bearing  race. 
the  front  bearing  inner track. 
n 
ST2045M 
ST2047M 
24  
						

							TRANSMISSION 
ASSEMBLE. 
Fitting reverse  idler shaft and gear. 
. I. I. 
37 
1. Position  the reverse  idler gear and thrust 
washer  in the  casing  with the thrust  washer 
and  the chamfer  on the  thrust  washer,  towards 
the  gear. 
2. Insert  the idler shaft  into  the casing  and 
through  into the 
idler gear  and  washer.  Ensure 
that  the roil pin  in the  shaft  lines
-up  with  the 
cut
-out  in the  casting,  then drive  the shaft  fully 
home. 
ST 2048 M 
3. Coat  the threads of the reverse  lever pivot 
bolt with  Loctite 270 and fit to the casing  and 
tighten  to the  correct torque. 
4. Fit the spacer  next to the casing. 
5. Fit the  lever  to the  pivot  whilst  ensuring  that 
the  slipper  locates  in the  reverse  idler gear 
groove. 
Fitting  mainshaft and input shaft. 
1. 
2. 
Fit the  input  shaft to the mainshaft  assembly 
ensuring  that the baulk  ring  engages correctly 
into  the 
third/fourth synchromesh  hub. 
Lower  the above  assembly  into the gear  case 
noting  that  the snap  ring 
on the front  and  rear 
bearings  locate against  a shoulder  in the 
casing. 
, .. . . .. . . .. , 
25  
						

							37 
Fitting layshaft. Fitting rear retainer  plate 
1. Hold the layshaft  above the mainshaft 1. Fit the  retainer  plate to the gearbox  and 
secure  the top 
of the plate  with the two bolts 
and  spring washers. 
2. Apply Loctite 270 (stud and  bearing  fit) to the 
socket  headed  screw threads  and secure  the 
lower  end 
of the retaining  plate. 
assembly 
and engage  the 
two sets of gears 
into  mesh  and 
roll the layshaft  into position  in 
the 
case. Check  that the rear  bearing  locates 
against 
the shoulder  in the  case. 
2. Wipe clean  the mating  faces of both  cases  and 
apply  Loctite  instant  Casket in accordance  with 
the  manufacturers  instructions. 
3. Lower  the  empty  case  into position over the 
gears  locating 
on the dowels. 
4. Loosely  secure the cases  with the  seven  bolts 
and  tighten  evenly to the  correct  torque 22 to 
28 Nm. (16  to 21 1bs.ft.). Clean  away any 
surplus  sealant. 
5. Refit the stand  to the  gearbox  and secure  in 
the  vice. 
-_ -I ,, .- ., .. ... .. -_ 1 
:- .: . .- 
Fitting  front cover ST2080M 
TRANSMISSION 
1. 
2. 
3. 
Fit the original  shim and spacer  to the  layshaft 
front  bearing. 
Fit  a new  joint  washer  to the  cover  and 
lubricate  the 
oi! seal lip. 
Taking  care not to damage  the 
seal lip, fit the 
cover  to the  gearbox  locating it over  the 
dowels.  Secure with the seven  bolts  and 
1. Remove  the nut  and  dummy spacer from the 
spring  washers  and tighten  evenly 
to the tays haf t . 
correct torque. 2. Fit  the  fifth  gear  to the  layshaft  with the large 
boss  to the  rear. 
3. To facilitate  the next  instruction, lock the 
gearbox  by engaging  first and fourth  gears. 
4. Fit a new  fifth gear  retaining  nut and  tighten  to 
the  correct  torque. 
Do not  stake  the nut  at 
this  stage. 
Fitting layshaft fifth  gear. 
ST2079M I 
26  
						

							TRANSMISSION 
-. -* x 5. Disengage the first  and fourth  gears. 
1. - 
37 
Fifth gear synchromesh end float. 
8. Using a feeler  gauge,  measure the clearance 
between  the washer  and  the sleeve. 
If 
necessary  exchange the washer for one  that 
will provide  a clearance of 0,075 
(0.003ins.) 
1. Fit  the  thrust  washer,  grooves  outwards, 
towards  fifth gear. 
2. Lubricate  and fit the  needle  roller bearing  to 
the  mainshaft. 
3. Fit the spacer  and fifth  gear. 
9. Remove  the  snap  ring, selective  washer  and 
sleeve. 
10. Wind  protective  tape round  the mainshaft 
splines  and fit the 
0 ring  seal  against  the 
synchromesh  hub retaining  plate. 
4. Fit the  fifth  gear  synchromesh  cone and hub 
assembly. 
5. Fit the  fifth  gear  synchromesh  hub retaining 
plate,  peg outwards. 
6. Omit  the 0 ring and fit the  sleeve  with the 
slot  over  the 
peg. 
7. Fit the  original  selective  washer and  retain  with 
the  snap  ring. 
ST2053M 
11. Refit the sleeve,  selective  washer and snap  ring 
and  remove  the protective  tape. 
27  
						

							F[ TRANSMISSION 
Fitting selector rails and forks. 5. Place  the reverse  gear cross-over lever in 
position in the gearbox  locating the fork end 
over the reverse lever operating pin. 
the  synchromesh  hub and gearbox  dowels. 6. insert the interlock  plunger into the 
first/second selector  rail. 
two bolts and plain  washers. 
1. Locate  the fifth  gear fork and bracket on to 
2. Secure  the fork  bracket  to the  gearbox  with 
3. Fit the  selector  rail interlock  plungers to the 
gearbox case. 
7. Push the firstkecond selector rail into the 
gearbox  and locate 
in the reverse  cross-over 
lever and selector  fork. Do not tighten  the 
fork clamp bolt at  this  stage. 
Note: the firsthecond fork clamp  bolt is not 
a set  bolt  unlike  the third/fourth fork clamp 
bolt. 
4. Fit the first/second and thirdlfourth selector 
forks. 
28  
						

							.- . ..,. . , .._,. ,.. . . . , .... . .. .... 
. .. 
TRANSMISSION 137 
8. Fit the firstkecond selector  jaw to the  rail and 
align  to accept  the retaining 
roll pin. 
9. Using  a suitable  drift, tap-in the roll pin  to 
secure  the jaw  and  rail. 
10. Repeat  instruction 9 for the third/ fourth 
selector  rail and  jaw. 
11. Push  the fifth  gear  selector  rail through  the 
gearbox  and the reverse  cross
-over lever. 
12. Fit the fifth  gear  selector  jaw to the  rail and 
align 
to accept  the roll pin. 
16 
13. Locate  the selector  rail into  the fifth  gear 
selector 
fork and secure with  the clevis pin, 
washer  and split 
pin. 
14. Secure  the jaw  to the  fifth  gear  selector  rail 
with  the 
roll pin. 
15. Push the  reverse  selector  rail through  the 
gearbox  and 
reverse cross-over lever  but do 
not  tighten  the lever 
clamp bolt  at this  stage. 
Continued 
17 I 
1 
29  
						

							1371 TRANSMISSION 
16. Fit the jaw to the  reverse  selector  rail, align 
the  holes,  and secure  with the roll pin  using  a 
suitable  drift. The pin must 
be inserted so that 
it 
is flush  with the underside of the jaw  to 
ensure  that the jaw  is adequately retained. 
17. Fit  the  reverse  gate spring  to the  selector  rail 
and  knock
-over  lever.  
18. Fit the  detent  balls and springs. 
Selector fork adjustment. 
1. Fit the  top cover gasket. 
2. Secure  the detent  spring retaining  tool and 
spacers  (manufactured  tool) to the  gearbox 
with  two 
8 x 50 bolts  and  plain washers. 
9. Repeat  instructions  4 to 8 to  adjust  the 
third/fourth selector fork and rail. 
Reverse  cross-over lever adjustment. 
The purpose of the following  adjustment is to 
ensure  that  when 
first gear is selected  the  outer 
member 
of the  first/  second  synchromesh  unit is 
not also  engaged  with the reverse  idler gear. 
3. Tighten  the bolts  to compress  the detent 
springs  until the retaining  plate contacts  the 
two spacers. 
4. Ensure that the firsthecond selector  rail and 
synchromesh  sleeve  are in the  neutral 
position.  Tighten  the clamp  bolt  sufficiently 
to 
eliminate any rock in the selector fork and 
move  the selector 
fork rearwards. 
5.  Scribe  a pencil  line 
on the rail at the  rear of 
the fork  yoke. 
6. Move  the fork forwards,  to the  original 
position  and scribe  another  line at the  rear 
of 
the yoke. 
7. Now scribe  a  line  midway  between  the two 
lines on the  selector  shaft. 
8. Move the selector fork rearwards so that  the 
yoke  coincides  with the centre  line and 
tighten  the clamp  bolt. 
1. Move the reverse  idler gear  thrust  washer  fully 
forward. 
2. Fit  the  manufactured  gauge to the  reverse 
idler  gear shaft 
so that it is between  the idler 
gear and  thrust  washer. 
3. Move the reverse  gear selector rail rearwards 
to engage  reverse gear. 
4.  Move  the cross
-over  lever  rearwards  to lightly 
nip  the  gauge  between  the reverse  gear  and 
thrust washer. 
5. Tighten  the reverse cross-over lever clamp  bolt 
and  return  the selector  rail to the  neutral 
position  and  remove the gauge. 
6. Move the first/second selector  rail rearwards  to 
select first gear. 
P --- 
Continued 
30