Land Rover Defender 90 110 Lt77s Workshop Supplement Rover Manual

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Ll77S MANUAL GEARBOX 
12. Using extractor tool 18G 705 and collets 18G 
705-7, withdraw 
layshaft bearings. 
ST3246M,  .  
DISMANTLE MAINSHAFT 
ST 
1. Remove circlip  retaining first  gear  assembly. 
4. With MS 47 press first gear assembly  from 
mainshaft. 
2. Remove  taper bearing,  bush,  needle  bearing, 
first  gear  spacer,  cone,  inner and outer  baulk 
rings. 
3. Remove circlip to release first and second  gear 
synchromesh...

137 MANUALGEARBOX DEFENDER 
5. Remove first and second  synchromesh  baulk 
rings. 
6. Using MS 47  and support  bars under second 
gear,  press 
off pilot  bearing, third, fourth 
synchromesh  second and third gear  assembly. 
ST3326M 64 i 
7. Remove  washer, third,  fourth  synchromesh, 
third  gear  baulk  ring,  split  needle rollers,  bush, 
needle  bearing and  second gear. 
8. Remove  snap ring,  spacer,  second  gear cone 
and  circlip. 
(3 
GEARBOX  CASINGS AND OIL PUMP L.. 7 
Degrease and clean...

LT77S MANUAL GEARBOX 
Centre plate 
1. Remove  bearing tracks. 
2. Inspect for  damage  and selector  rail  bore for 
wear. 
3. Temporally  fit  reverse  shaft gear and  lever  and 
check  clearance  between slipper and  lever 
does  not  exceed 
0,20 mm (0.008 in). 
3. Check  oil pick  up pipe  for obstruction  but  do 
not  remove. 
4. Remove drain  plug assembly. Clean and  renew 
filter  and washers  if necessary. 
5. Renew  oil  seal. 
6. Renew Ferrobestos bush. 
WARNING:  This bush  contains...

I 37 MANUALGEARBOX DEFENDER 
9. Fit oil  seal to  housing,  lip side  leading, using 
18G 1422. Apply SAE 40 oil to lip. 
10. Assemble  gears  to  oil pump  and fit  cover. 
ST3254M 
GEAR  CHANGE HOUSING 
1. With a length  of tube,  release the  bias spring 
from  adjusting  screws. 
2. Remove  bias spring  adjusting screws. 
ST2186M 
3. Drive-out roll pin to remove bias spring. 
4. Remove  gear lever  extension from  lower  gear 
lever. 
5. Remove bolt and special  washer to  remove 
lower  gear lever....

LT77S MANUAL GEARBOX 
,  7. Clean and examine all components and  renew 
8. Assemble  above parts In reverse order  using 
NOTE: Ensure  spring  loaded pad is 
properly  located and that  the lever is 
fitted to the housing  with the pad  on the 
opposite  side to the  bias  spring.  Leave  bias 
spring  adjusting  screws slack until assembly 
of 
gearbox. 
where  necessary. 
multi
-purpose  grease on gear  lever. 
Remote  gear lever housing. 
1. Release  socket headed  screw to remove 
trunnion. 
1 .: ,...

1 DEFENDER 
37 MANUAL GEARBOX - 
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1.: 
-_ 
GEAR SELECTOR  HOUSING 
t I 
0,: 
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1. Gear selector housing 
2. Gasket 
3. Roll pin 
14. Reverse  gear plunger 
15. Gear lever Seating 
16. Trunnion 
19. 0 ring 
20. Selector shaft 
21. Quadrant 
22. Roll pin 
23. Rollers 
i  

LT77S MANUAL GEARBOX 
Reverse gear plunger  assembly. 
1. Remove  plug  spring  and ball. 
2. Remove circlip to  release plunger and  spring. 
3. Clean and examine components. 
4. Assemble  plunger and  spring  with multi-purpose 
grease and  secure  with circlip. 
5. Lubricate and fit  detent  ball and spring  with light 
oil.  Apply  Loctite 290 to  plug threads  and fit. 
6. Check  that  plunger  returns when depressed. 
ST2201 M 
Transfer  gear housing. 
1. Remove  the four screws  and remove  gaiter...

137 MANUALGEARBOX 
15 I 
17 
ST 2185 M 
1. Gaiter  retaining  screw - 4 off, 
2. Gaiter. 
3.  Gaiter  support  plate. 
4. Gate plate. 
5. Gasket. 
6.  Split  pin. 
7. Clivis  pin. 
8.  Circlip  retaining  Nylon seat. 
9. Gear lever ball. 
10. 
Nylon seat.  11. 
Cross  shaft. 
12.  Gear  lever. 
13.  Gear  change  housing. 
14.  Non
-mettalic  bushes. 
15.  Counter  sunk screws. 
16.  End  cover. 
17.  Detent  spring and plate. 
18.  Selector  fork. 
19. 
0 rings. 
-12 
DEFENDER  

LT77S MANUAL GEARBOX 
SYNCHROMESH ASSEMBLIES 
Third
-fourth and  fifth  gear  synchromesh. 
NOTE: the  above  assemblies  are the 
same except that  fifth  gear synchromesh 
has  a retainer plate. 
1. Mark relationship  of inner  and outer  members. 
2. Remove  wire  clip  from  both  sides of assembly. 
3. Remove  slippers  and separate the  two 
members. 
4. Examine  all parts  for damage  and wear 
including wire  clips for tension. 
5. Check no radial movement exists  between  inner 
members  and...

137 MANUALGEARBOX DEFENDER 
First-second synchromesh 
8. Repeat  instructions 1 to 6 for  third-fourth 
synchromesh. 
9. Examine  step in each of outer  splines. 
10. Check  that  the  step on  both  sides of the 
internal  splines  are  sharp  not rounded. 
NOTE:  this applies  only to splines  on 
selector  groove side 
of member. 
 ST3244M lb 
11. Fit inner  member  to outer so that  the  wide 
splines  of  inner  member are under  the  spur 
gear teeth. 
r; 12. Fit the  slippers  and secure  with  a...