Land Rover 90 110 Workshop Rover Manual
Here you can view all the pages of manual Land Rover 90 110 Workshop Rover Manual. The Land Rover manuals for Automobile are available online for free. You can easily download all the documents as PDF.
Page 271
Always have a fire extinguisher containing FOAM CO2 GAS, or POWDER close at hand when handling or draining fuel, or when dismantling fuel systems and in areas where fuel containers are stored. Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system. Whenever petroVgasoline is being handled, draincd or stored, or when fuel systems are being dismantled all forms of ignition must be extinguishcd or removed, any head-lamps used...
Page 272
. Special Service Tools The use of approvcd special scrvice tools is important. Thcy are essential if scrvicc opcrations arc to be carricd out cfficicntly, and safely. The amount of timc which thcy save can be considcrable. Every special tool is designcd with the closc co-operation of Land Rover Ltd., and no tool is put into production which has not been tested and approvcd by us. New tools are only introduced wherc an operation cannot be satisfactorily carried out using cxisting...
Page 274
1371 LT77 FIVE SPEED GEARBOX 25. Remove the three nuts and bolts securing the transfer box L.H. and R.H. mounting brackets to the chassis. 26. Remove the nuts retaining the brackets to the mounting rubbers and remove the brackets. 27. Lower the hoist sufficiently to allow the transfer lever to clear the transmission tunnel aperture. 28. Disconnect the four-wheel drive indicator electrical lead (bullet connection). 29. Remove the cleat retaining the reverse light...
Page 275
LT77 FIVE SPEED GEARBOX (37 I 61. Fit the handbrake cable using a new split pin to secure the clevis pin. Grease the clevis and tighten the outer cable lock nuts. 62. Connect the speedometer cable. 63. Check that the three drain plugs are tight and remove the main gearbox and transfer box filler level plugs. Fill the main gcarbox with approximately 1,76 litres (3 pints) of a recommended oil or until it begins to run out of the filler level hole. Fit and tighten...
Page 276
171 LT77 FIVE SPEED GEARBOX ST542M 11. Using tools 186705 and 186705-1A remove the oil seal collar. / 12 ST543M 12. Remove the ten bolts and spring washers securing the rear cover to the gearcase; withdraw the rear cover and discard the gasket. 13. Fit two dummy bolts (8 x 35 mm) to the casing to retain the centre plate to the main case. 14. Remove the oil seal collar ‘0’ ring from the mainshaft. 15. Withdraw the oil pump drive shaft. 16. Remove the two...
Page 277
LT77 FIVE SPEED GEARBOX 31. Remove the dummy bolts and carefully lift the gearcase, leaving the ccntre plate and gear assemblies in position. Discard gasket. 32. Insert two slave bolts and nuts to retain the centre plate to the stand; and remove the circlip, pivot pin, reverse lever and slipper pad. 33. Slide the reverse shaft rearwards and lift off the thrust washer, reverse gear and reverse gear spacer. 34. Lift off the layshaft cluster. 35. Remove the input shaft...
Page 278
LT77 FIVE SPEED GEARBOX Mainshaft 42. Remove the centre bearing circlip. 43. Using press MS47 and any suitable metal bar, remove the centre bearing, first gear bush, first gear and needle bearings and first gear synchromesh cone. Input shaft ST 44. If a difficulty is experienced in removing the first and second gear synchromesh hub, locate underneath the sccond gcar with a suitablc tool; and extract the complete synchromcsh hub and second gear assemblies using...
Page 279
~~77 FIVE SPEED GEARBOX 137 I Gear selector housing - Early models (Not illustrated) 3- - ;c ::: Centre plate .&&L\.S v,, 62. Remove the layshaft and mainshaft bearing tracks from the centre platc and reverse pivot post. Main gearbox casing 63. Remove the mainshaft and layshaft bearing tracks 64. Remove the plastic oil trough from thz front of from the main casing. the casing. Selector rail 65. The selector rail is supplied complete with first and second selector fork,...
Page 280
LT77 FIVE SPEED GEARBOX Fifth gear plunger assembly - Early models only 81. Remove the plug, long spring and detent ball from the fifth gear plunger. 82. Remove the circlip which retains the fifth gear plunger, pull out plunger and short spring. Keep all parts labelled and separated from the reverse plungerassembly. 82 86. Inspect all gear teeth for chipped or broken teeth, or showing signs of excessive wear. Inspect all spline teeth on the synchromesh...