Land Rover 90 110 Workshop Rover Manual
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LT 95 FOUR SPEED GEARBOX 1371 OVERHAUL LT 95 FOUR SPEED GEARBOX The following overhaul instructions assume that the gearbox is removed from the vehicle and the oil drained. Remove the clutch slave cylinder, release mechanism and bearing assembly, stand the gearbox on a wood block on the bell housing end. REMOVE AND OVERHAUL SPEEDOMETER DRIVE HOUSING 1. Remove the brake drum retaining screws and 2. Remove the four bolts retaining back plate, withdraw the drum. remove oil catcher and back plate assembly. 11. Drive out the rear output shaft, using a hide mallet 12. Slide off the spacer and speedometer worm. on the threaded end. 3. Remove the eight bolts and withdraw the 4. Remove the speedometer spindle housing. 6. Take off the 0 ring seal. 7. Remove the thrust washer. 8. Withdraw the oil seal. speedometer drive housing. 5 1 ift niit the driven opar and cnindlr b--. -..- r-*---. d. Y... VI. L..V .A..... . .. ::,-. . . . 9. Remove the locking nut, using a flange tool, .. . -, . .., washer and felt seal, output coupling flange to output shaft. .. :. .:. 10. Withdraw the coupling flange complete. ST1025M 13. Withdraw the oil shield. 14. Prise-out the oil seal. 15. Remove the circlip. 16. Tap out the ball bearing race. 39
LT 95 FOUR SPEED GEARBOX ST1204M I# Check differential pre-load This check must be carried out if a replacement speedometer drive housing is to be fitted. The check is also required if a replacement gcarbox, differential unit or diffcrcntial unit bearing is being fitted. 17. 18. 19. 20. 21. 22. - - Measure and record the thickness of the new joint washer for the speedometer drive housing. Offer the spcedometer housing, less joint washer. to the gearbox. Measure the clearance between the drive housing and gearbox joint faces. This must be 0,lO to 0,15 mm (0.004 to 0.006 in) more than the recorded thickness of the new joint washer. With the gasket fitted and the bolts tightened to 3 kgf.m (22 Ibf.ft) a final rollingresistancc check should be made using a spring balance and string wrapped round the differential case. The resistance should be 14 -16 Ibs (6-7 kg). The differential lock must be disengaged to allow free rotation of the unit whilst making this chcck. To adjust the joint face clearance, adjust the thickness of shimming fitted behind the rear bearing outer face as follows: instructions 21 and 22. Drive out the bearing outer race. Withdraw the shim washer and selcct a replacement of the required thickness. Shim thickness range is 1,65 to 2,80 mm (0.065 to 0.110 in) in 0,05 mm (0.002 in) stages. Assemble the housing 23. Fit the rear output shaft ball bearing and circlip. 24. Press in the output coupling flange oil seal, open face first, until the seal plain face just clears the chamfer on the seal housing bore. 25. Fit the oil shicld, which must be a close fit on the speedomcter housing. 26. Fit the speedometer worm Iollowed by the spacer. 27. Fit the rear output shaft. 28. Fit the coupling flange. 29. Fit the felt seal, plain washer and locking nut to secure the output flange and tighten to the correct torque. 30. Assemble the following parts to the speedometer spindle housing: 31. Fit the oil seal. 32. Fit the thrust washer. 33. Fit a new 0 seal. 35. Fit the speedometer spindle housing assembly to #%i w,. .I 34. Fit the speedometer driven gear and spindle. . .I the drivc housing. Assemble speedometer drive housing to gcarbox 36. Place a new joint washer in position. 37. Offer the drive housing to the gearbox and engage the rear output shaft splines in the differential unit. 38. Position the flat on the drivc housing adjacent to the flat on the intermediate shaft. 39. Secure the assembly with eight bolts and evenly tighten to the correct torque. 40. Fit back plate assembly. 42. Tighten special bolts to 55 to 60 Ibf.ft (75 to 80) $1. oil catcher and with dyiosii, noting that plain washers are fitted. 40
LT 95 FOUR SPEED GEARBOX 1371 ::‘:?2 REMOVE AND OVERHAUL MAINSHAFT +:... ~. I TRANSFER GEAR Special tool: lSC1388 - mainshaft output gear puller y., .:, c .: 1. Remove thc mainshaft rear bearing housing. 2. Lift out the roller bearing. 3. Remove the snap-ring. 4. Withdraw the shim washer. 5. The transfer gcar is retained on the splines with Loctite 275. Use a puller 1861388 to withdraw it. NOTE: The roller bearing outer race is located by a roll pin which must be punched-out before the race can be removed. Assembling Fit the transfer gear to the mainshaft. Fit the shim washer and snap-ring. Check the end -float between the shim washer and snap -ring. End-float to be 0,050 mm (0.002 in) maximum. Shim washer range 1,s to 2,O mm (0.071 to 0.079 in) in 0,05 mm (0.002 in) stages. Fit the roller bearing and rear bearing housing. REMOVE AND OVERHAUL INTERMEDIATE GEARS ASSEMBLY Special tool: R01003 - slave intermediate shaft 1. Remove the speedometer drive housing. 2. Remove the gearbox bottom cover. 3. Screw a suitable extractor into the 8 mm threadcd hole provided in the intermediate gear shaft. 4. Hold the intermediate gear cluster in position and withdraw the shaft. 5. Insert the slave shaft R01003 to retain together the gears assembly. 6. Withdraw the intermediate gears assembly. 7. Slide the thrust washers, bearings and gears from 8. The input gear and outer member is a riveted the slave shaft. assembly and no dismantling is permitted. 9. Remove the ‘0’ ring seal from the intermediate gear shaft. 10. Wash and degreasc all parts and inspcct for wear and renew if necessary. When new, the thrust bearing washers have a lead/tin coating, if this only has worn away there is no need to renew them. Assemble intermediate gears 11. Place the slave shaft on the bench, extractor thread end uppermost. 12. Fit a pear-shaped thrust washer, inner ring and a thrust bearing washer to the shaft (ring grooved face downwards). 13. Fit a needle-roller bearing and the ‘high’ gear (plain face first) to the shaft. 41
LT 95 FOUR SPEED GEARBOX -_ I ST12 1 OM 14. Position a thrust bearing washer on the ‘high’ gear. 15. Fit a spacer, nccdlc-roller bearing and a further spacer to the input gear inner member. 16. Position the assembled input gear on the shaft and engage the lower spacer in the previously positioned thrust bearing washcr. 17. Locatc a thrust bearing washer over thc upper spacer. 18. Fit a needle roller bearing and the ‘low’ gear (plain side last) to the shaft. 19. Fit the remaining thrust needle bearing, inner ring and thrust washer (ring grooved face upwards). 42 ST121 20. When the foregoing bearing clearance check has been completcd. slidc the gcars and slave shaft assembly into the transfer gearbox and engagc thc selector forks. 21. Withdraw the slave shaft and lubricate the bearings through the shaft aperture. 22. Fit the intermediate shaft and ‘0’ ring seal with the flat on the shaft toward the differential unit. 23. Measure the clearance between the rear thrust washer and the gear casing. This must be 0,15 to 0,23 mm (0.006 to 0.009 in). 24. Adjustment is carried out by substituting one or both of thc thrust washcrs. The washers are available in 33.5 mm (0.139 in), 3,63 nini (0.143 in) and 3,74 mm (0.147 in) thicknesses. 25. Refit the gearbox bottom cover. 26. Refit the speedometer drive housing. 1 ST1213M
. .c. .. .. , ..*. .,? .ti .? .. .. ... ..: LT 95 FOUR SPEED GEARBOX REMOVE AND OVERHAUL DIFFERENTIAL UNIT Special tool: 18G47BB -bearing extractor 1. Select the differential lock. 2. Rcmove the differential lock actuator assembly 3. Remove the front output shaft and housing. 4. Remove the speedometer drive housing. 5. Remove the intermediate cluster assembly. 6. Remove the differential assembly. NOTE: During dismantling it is essential that all components are marked in their original position and relative to other components, so that if original components are refitted, their initial setting is maintained. 7. Press off the roller bearings using tool 18G47BB. 8. Withdraw the high-speed gear, which is secured by Loct i tc. I I ST1215M 9. Remove the fixings, low-speed gear to casing. 10. Withdraw the gear. 11. Remove the casing securing bolts. 12. Lift off the rear case assembly (and oil retaining ring - later gearboxes). 13. Withdraw the side gear (and thrust washer - later boxes). 14. Slidc out the cross-shafts and rcmovc the bevel pinions and thrust washers from the front case assembly. 15. Withdraw the side gear (and thrust washer - latcr boxes) to dismantlc the front case assembly. - ST1216M NOTE: From gearbox numbers 1300 3481A and 1700 0007A the following modifications have been made to the differential. A. Introduction of side gear bushes. B. Improved thrust washers. C. Addition of thrust washer on side gears. D. Modified cross pins. E. Addition of oil retaining ring. The new differential part number FRC 7740 is only interchangeable with superceded unit part number 594 340. 43 ST1799M
LT 95 FOUR SPEED GEARBOX NOTE: If replacements are required, replace the following items 16 and 17 as sets. 16. Bevel pinions and side gears (set of six). 17. Cross -shafts (set of two). 18. Check the gear teeth for damage. 19. Check all parts for satisfactory general condition including the sidc gear bushcs. NOTE: The differential case halves are a matched pair, and halves must not be changed individually. Assemble differential to gearbox 27. Refit the differential unit. 28. Refit the speedometer drive housing. 29. Refit thc frofit output shaft and housing. 30. Rcfit the diffcrential lock actuator assembly NOTE: If a replacement differential unit is being fitted, carry out the ‘Differential hearing pre -load check’, described in ‘Speedometer drive housing - Overhaul’. Assemble differential CAUTION: It is essential that during the following assembly all components are well lubricated with new oil of the correct grade. 20. Fit a sidc gear into the rear casing. 21. -Fit a side gear into the front casing. 22. Fit the bevel pinions, thrust washers and cross- shafts into the front casing. 23. Fit thc rear casing to the front casing. Tighten the bolts evenly in sequence to thc correct torquc. Use Loctite 275 on threads. 24. Offer the low gear to the differential casing. 25. Align the fixing holes and fit the bolts evcnly in sequence to the correct torque. Usc Loctite 26. Fit the roller bearings and refit the diffcrential unit. REMOVE AND OVERHAUL TRANSFER GEAR LEVER AND CROSS -SHAFT 1. Remove the top cover. 2. Slacken the selector finger pinch bolt. 3. Drive out the retaining pin, gear lever to cross- 4. Withdraw the gear lever. 5. Withdraw the cross-shaft and spacer. 6. Lift out the selector finger. 7. Remove the retaining plates. 8. Withdraw the scaling rings. shaft. ST121 Assemble gear lever and cross-shaft 9. Position the selector finger in the gearbox. 10. Fit the cross-shaft and spacing collar and engage-i the selector finger. side of the gearbox. 11. Fit the sealing ring and retaining plate at the R.H. 12. Fit the gear lever and retaining pin. $5 *- ,/ NOTE: If the differential case or bearings have been replaced, carry out the ‘Differential bearing pre- load check’. 44
LT 95 FOUR SPEED GEARBOX 137( 13. Fit the remaining sealing ring and retaining plate. 14. Tighten the selector finger pinch bolt. 15. Select ‘High’ transfer range, that is, the larger intermediate gear engaged. 16. Slacken the selector finger bolt. 17. Rotate the cross-shaft until the gear lever is inclined 45 degrees to the vertical position. W17 ACO ST 1 21 9M 1- 18. Tighten the selector finger pinch bolt. 19. Fit the top cover using a new joint washer and evenly tighten the retaining bolts. . .I... . .. .... . .. . . , . . . . . .. . REMOVE AND OVERHAUL TRANSFER BOX SELECTORS AND SHAFT 1. Remove the speedometer drive housing. 2. Remove the transfer gearbox top cover. 3. Select ‘Low’ range transfer gear. 4. Drive out the retaining pin from the front selector fork sufficient to free the fork. 5. Ease the differential unit to the rear. 6. Push the forward selector fork forward on the shaft. 7. Pull to the rear on the rear selector fork to move the selector shaft out of engagement with the detent balls in the casing rear face. 8. Remove the pinch bolt on the rear fork. 9. Partially withdraw the selector shaft and lift out the selector forks. 1.. 10. Remove the retaining pin from the front fork. .. .. . . .h.,. . 11. Withdraw the selector shaft, closing the shaft housing by hand to prevent the detent balls from dropping into the casing. ,. 12. Withdraw the two detent balls. 13. Lift out the spacing rod and spring. 14. Remove the blanking plug. 15. Withdraw the detent spring from the cross drilling. Assemble shaft and selectors 16. Position the detent spring in the inncr bore in the 17. Locate the detent ball on the spring. 18. Enter the selector shaft, push the ball against the spring and push in the shaft. 19. Fit the detent ball, spring and spacing rod to the vertical drilling. 20. Position thc rear selector fork, plain face to rear, in the gearbox. 21. Position the front selector fork, extended boss to the rear, in the gearbox. 22. Align the retaining pin holes and engage the selector shaft in the selector forks. 23. Fit the retaining pin, front fork to shaft. 24. Set transfer gears in ‘Neutral’ position. 25. Adjust the rear fork position until there is 0,12 to 0,25 mm (0.005 to 0.010 in) clearance between the front face of the rear fork and the rear face of the input gear inner member. cross drilling. 26. Tighten the rear fork pinch bolt. 45
37 27. Fit the blanking plug to the cross drilling. 28.-Fit the transfer box top cover using a new joint washer and evenly tighten the bolts to the correct torque. 29. Fit the speedometer drive housing. LT 95 FOUR SPEED GEARBOX RER E ND OVER€ SHAFT AND HOUSING IUL FRONT OUTPUT Remove output shaft assembly 1. Remove the differential lock actuator assembly. 2. Remove the six retaining bolts, spring washers and 3. Withdraw the output shaft and housing complete. 4. Lift out the lock-up dog clutch. gasket. 0 Overhaul assembly 5. Hold the output shaft in a vice or use a flange & restraining tool and remove the flange retaining nut and washer. 6. Withdraw the coupling flange complete with mudshield. 7. If required, press off the mudshield. 8. Press out the shaft toward the rear. 9. Withdraw the oil seal. 10. Remove the circlip. 11. Withdraw the output shaft bearing. 12. Wash and degrease all parts, examine for wear and renew as necessary. ST 1223M Assemble output shaft assembly to housing 13. Fit the output shaft bearing and secure with the 14. Fit the oil seal, lip side towards the bearing. 15. Press in the output shaft from the rear. 16. Fit the coupling flange complete with mudshield and flange bolts. Secure with the locking nut to the correct torque. ci rcl i p. , 46
.. LT 95 FOUR SPEED GEARBOX b- 37 REMOVE AND OVERHAUL BELL HOUSING AND REMOVE AND OVERHAUL GEAR CHANGE CLUTCH RELEASE SELECTORS I. Withdraw the locating staple from the clutch 2. Lift out the release sleeve and bearing assembly. 3. Remove the bell housing fixings and make a note 4. Withdraw the bell housing complete with clutch 5. If required, remove the push rod clip and the release slecve and release lever. of the position of each bolt and nut. release lever. spring clip and withdraw the clutch release lever. 1. Remove the bell housing. 2. Select neutral, remove the reverse light switch and remove the gearbox top cover and joint washcr. 3. Lift out the dctent springs. 4. Withdraw the detcnt balls, using a small magnet or 5. Slacken the pinch bolt securing the reverse selector 6. Drive out the four retaining pins until the shafts are an air blast. finger. free in the selectors. ST1225M Assemble clutch release and bell housing 7. Tap out the selector shafts. 6. If removed, fit the release lever spring clip. 7. Apply a thin film of Unipart Universal or other suitable jointing compound around the three selector shaft holes in the bell housing rear face. 8. Fit the bell housing, locating on the dowels. 9. Apply a thin film of molybdcnum disulphide grease onto the front cover extension sleeve. 10. Fit thc rclcase sleeve and bearing assembly. 11. Fit the locating staple to the clutch reiease sleeve and lever. 8. Withdraw the selector jaws and forks. 9. Withdraw the two interlock plungers from the cross -drilling. 10. Rcmove the lock-wired pivot bolt. 11. Lift out the reverse cross-over lever. Overhaul Examine all parts and renew if worn. Renew thc detent springs. Ensure that the retaining pins are an interference fit, if not, renew. .. ST 1 47
1371 LT 95 FOUR SPEED GEARBOX Assemble gear change selectors 12. Withdraw the retaining pins from the selector jaws. 13. Engage the cross-over lever and locate fully in the groove in the reverse idler with the peg in the top of the cross -over lever fully in the selector finger. 14. Start the pivot bolt in the lever threads. Should it not start properly move the lever away from the selector finger but not out of engagement with the idler. 15. Locate the first/second gear selector fork in the groove in the outer member, with the boss on the fork to the rcar. Position the boss to the R.H. side of the box. 16. Locate the third/fourth gear selector fork in the groove in the outer member. Position the fork with the retaining pin entry hole at the top R.H. side. 17. Fit the third/fourth gear selector shaft and interlock pin assembly and secure to the selector 18. Fit the two interlock pins to engage in the grooves each side of the third/fourth gear selector shaft. 19. Position the reverse stop hinge plate and selector jaw in the gearbox, adjacent to the third/fourth gear selector jaw. 20. Fit the reverse gear selector shaft and engage the selector jaw and hinge spring. 21. Push the shaft home and engage the reverse cross- over lever selector finger. Do not secure the pinch bolt at this stage. 22. Secure the revcrse gear selector jaw to the shaft with a retaining pin. . fork with a retaining pin. 24 23 2a01 15 25 A+- +* ST 1227M 23. Posi!i~n thp first,/secogd up?ir cplprtnr iaw in the b- w--Va J gearbox. 24. Fit the first/second gear selector shaft; engage the selector jaw and selector fork as the shaft is pushed home. 25. Fit the retaining pins, fitting the rear pin first. 26. Move the reverse shaft forward until the selector jaw abuts the casing. 27. Holding the reverse shaft as described in the previous item, move the reverse selector finger forward on the shaft until it abuts the casing, then move it rearward until it is just clear of the casing. 28. Place a 0,25 mm (0.010 in) feeler gauge between the upper edges of the reverse and third/fourth selector jaws. NOTE: The edges of the selector jaws taper slightly, therefore, it is important that the feeler gauge is positioned between the upper edges. 29. Hold the reverse and third/fourth selector jaws together to retain the feeler gauge, then rotate the reverse selector finger until it abuts the third/fourth selector shaft and tighten the pinch bolt. 30. Wire lock the cross-over lever pivot bolt. 31. When fitting the hinge spring to the reverse stop hinge, first engage the large hook around the selector shaft, as illustrated, before fitting the small hook to the reverse stop hinge pin. 48