Land Rover 90 110 Workshop Rover Manual
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Page 321
LT95 FOUR SPEED GEARBOX (371 6. Lift out the reverse idler gear assembly. 7. Remove the circlip and plain washer. 8 Lift out the needle rollcr bearings and further plain washer. 9. Withdraw the remaining circlip. 9 32. Fit the detent balls and springs. 33. Selcct neutral and using a new joint washer, fit thc gearbox top cover and secure with the eight bolts, T and evenly tighten to the correct torque. STl23 1 M 34. Fit the reverse light switch 35. Fit the bell...
Page 322
LT 95 FOUR SPEED GEARBOX REMOVE AND OVERHAUL FRONT COVER AND OIL PUMP Service tools: R01005 - Centralising tool 18G134 - guide and 18G134DG - assembly tool for fitting oil seal and oil feed ring. 1. Lift out the retainer staple from the clutch release bearing assembly and the release lever. See clutch release overhaul. 2. Withdraw the release bearing assembly. 3. Remove the slave cylinder pushrod. 4. Remove the spring clip. 5. Withdraw the clutch release lever. 6....
Page 323
LT 95 FOUR SPEED GEARBOX (37( Fit cover assembly to gearbox 19. Position the layshaft bearing shim washer. 20. Position the front cover assembly and loosely fit the fixings. 21. Fit the oil pump drive gear to engage the drive square in the layshaft. 22. Fit the oil pump cover and joint washer and fit the fixing screws and washers and carefully tighten to the correct torque. 23. Fit the gauge R01005 to align the primary pinion with the bell housing. 24. Visually...
Page 324
LT 95 FOUR SPEED GEARBOX REMOVE AND OVERHAUL PRIMARY PINION 1. Remove the bell housing. 2. Remove the front cover and oil pump assembly. 3. Remove the bearing plate assembly. 4. Remove the circlip. 5. Lift off the shim washer. 6. Press out the primary pinion. ST 1 240M 7. Withdraw the bearing retaining plates and serrated 8. Press out the primary pinion bearing. bolts. ~ ~~~ ~ ~~ ~ Assemble primary pinion 9. Check that the orifice drilkd in the oil tube is clear. 10....
Page 325
LT 95 FOUR SPEED GEARBOX 1371 - -. ..._ __ ,.~ ., .1-. REMOVE AND OVERHAUL THE MAINSHAFT .....,. . ., ASSEMBLY .. . . ..L ...,. ., .. ... ..-. . Special tool: 1861388 -extractor for mainshaft spacer and gear 1. Remove the bell housing. 2. Rcmove the front bearing plate. 3. Remove the main gearchangc sclectors. 4. Removc the mainshaft rear bearing housing and 5. Remove the bottom cover from the transfer roller bearing. gearbox. NOTE: At this stage in the dismantling, on...
Page 326
LT 95 FOUR SPEED GEARBOX Overhaul mainshaft assembly Dismantle 15. Withdraw thc first-speed gear, thrust washers and roller bearings from the rear of the shaft. 16. Remove the snap-ring and shim washer from thc front of the shaft. 17. Lift off the third/fourth gears synchromesh assembly. 18. Withdraw the third and second-speed gears and the associated thrust washers and needle-rollcr bearings. 19. Dismantle the third/fourth gears synchromesh assembly, first pushing down...
Page 327
.,.. ,. .. ., -... . r ,: 5 -.: : . . .: . ,. .. LT95 FOUR SPEED GEARBOX 137 34. Fit a scalloped thrust washer, a thrust needle bearing and a further scalloped thrust washer. 35. Fit a radial needle bearing and the third-specd gear. 36. Fit a scalloped thrust washer, a thrust needle bearing and a further scalloped thrust washer. 37. Position a synchromesh cone onto the third-speed gear. 38. Fit the synchromesh unit, coned face to rear. Set end-float of gears 39....
Page 328
137 I LT 95 FOUR SPEED GEARBOX 55. Engage the shaft into the main bearing. 56. Engage the first/second gear synchromesh outer member and the reverse idler gear. 57. Push the mainshaft home enough to allow the mainshaft spacer to be locatcd on the rear end, with the spacer larger diameter forward of the transfer gear lever cross -shaft. 60 58. Re-position the first-speed gear, thrust washers and thrust needle bearing correctly on the mainshaft. 59. Push the mainshaft...
Page 329
LT 95 FOUR SPEED GEARBOX ,:.:.:.. i.: *:, 1 ... ... ..,; 7. Extract the layshaft rear bearing outer member from the gearbox casing, extiaetor 186284 and adaptor 18G284AR. 12. Press the rear bearing outer member into the 13. Enter the front bearing outer member into the .. I. :..:! gearbox casing. front bcaring plate. DO not fit fully in at this stage. 37 . 8. Withdraw the bearing inner members from the layshaft. Extractor 18647 press and 18G47BA col tars. n ST 1258M...
Page 330
37 21. Measure the rolling resistance of the layshaft, using a spring balance and a cord coiled around the layshaft larger diameter. The rolling rcsistance must be 7 to 3,38 kg (6 to 7.5 Ibs). REMOVE AND OVERHAUL DIFFERENTIAL LOCK ACTUATORASSEMBLY 1. Remove the four bolts and withdraw the assembly from front output shaft housing. 2. Remove the detent spring and ball. LT 95 FOUR SPEED GEARBOX 22. To adjust the pre-load, fit a replacemcnt shim or suitable thickness to...