Land Rover Defender 90 110 Lt77s Workshop Supplement Rover Manual

LT77S MANUAL GEARBOX 
OVERHAUL 
CHECKING BAULK RING CLEARANCES 
17 
Check  clearance of all  baulk  rings and gears  by 
pressing  the  baulk ring against  the  gear  and 
measuring the 
gap. The  minimum clearance should 
be 
0,38mm (0.015in). 
First  gear  Third 
gear 
ST 
Fourth  gear 
second  gear 
ST32 26M 
Fifth gear 
ST3259M 
ST3261M  

I 37 MANUALGEARBOX DEFENDER 
INPUT SHAFT 
1. Examine the  gear and  dog teeth  for wear  and 
2. Polish oil  seal track  if necessary. 
3. Using 18G 284 AAH and 18G 284 remove  pilot 
damage. 
bearing track. 
18G284AAH  
18G284 
ST3278M 
4. Using 18G  47BA and MS 47 remove  taper 
bearing. 
6. Using Press MS 47, Collets 18G 478 and 
adaptor 
18G 47 BAX fit  a new  taper  bearing. 
NOTE:  ensure  that the bearing is 
supported  by the lip inside 18G 47 BA. 
MAINSHAFT 0 
ST3279M 
1. Examine bearing...

LT77S MANUAL GEARBOX 
MAINSHAFT GEAR END FLOAT  CHECKS 
Third gear end-float. 
1. Hold mainshaft  in vice  front end downwards. 
2. Fit front  circlip for first-second  synchromesh. 
3.  Fit second  gear  cone. 
4. Fit spacer. 
5. Fit  snap ring. 
1. Fit  needle roller to third  gear. 
2. fit  third  gear bush to third  gear. 
3. Place  gear on flat surface,  bush flange 
downwards, and  with 
a straight edge across 
gear  check  clearance  between straight  edge 
and gear. 
Not to  exceed 0,20...

1 37 MANUALGEARBOX DEFENDER 
3. Fit first-second  synchromesh  hub,  fork groove 8. Fit first  gear  bush. 
4. Fit circlip. 
10. Fit circlip. 
uppermost. 
9. Fit 
dummy  bearing. 
ST3231 M - 
First-second  synchromesh  assembly 
S T3 2 57M 
5. Fit first  gear  inner  and outer  baulk  ring. 
6. Fit cone. 
7.  Fit  spacer.  11. 
Check  clearance between dummy  bearing  and 
bush. 
Not to exceed 0,75mm (0.003in). 
12.  Remove circlip,  dummy bearing and  bush. 
9 
8 
7 
1---7 ST3 253M I I 
Selective  first...

LT77S MANUAL GEARBOX 
3. Place straight  edge  across  gear and check 
clearance  between  gear and straight 
edge.Not 
to exceed 0,20mm (0.008in). 
/ 
ST3255M 
ASSEMBLING MAINSHAFT 
1. With the  first-second  synchromesh  hub and 
spacer  in position,  assemble the  rear end 
of the 
shaft. 
2.  Fit the  roller bearing and bush  to first  gear. 
3. Fit first  gear to mainshaft. 
ST3229M 
 37 
First  gear  assembly 
1 
3 
4. Fit the  taper  bearing to  mainshaft  using MS 47, 
collets 18G 47 BA and...

37 MANUAL GEARBOX  DEFENDER 
CAUTION: Ensure that the slots  in the 
baulk  ring align  with the synchromesh 
slippers  while pressing  on the  bearing. 
A 
5. Invert  mainshaft and  press  assembly back 
against circlip. 
5 ’2 
7. Posltlon mainshaft in vice, rear  end downwards 
and fit  second  gear needle  roller,  and second 
gear. 
8. Fit  third  gear  bush. 
9. Fit third  gear needle rollers. 
10. Fit third  gear. 
11. Fit third  gear baulk  ring. 
MS 47’ 
 
5 
w 
LJ ST3264M 
NOTE:  Instruction 5...

LT77S MANUAL GEARBOX 
12. Fit third-fourth  gear synchromesh  hub. 
13. Using MS 47 with supports under first  gear, 
press the  spigot  bearing 
on to shaft. 
-1 2 
ST3266M U/ /  
LAYSHAFT 
1. Examine the layshaft for  wear  and damage. 
2. Press bearings on to layshaft using MS 47 and 
supporting  bars. 
MS.47 i 
REVERSE GEAR AND SHAFT 
1. Remove  one circlip  from  the  idler  gear  and 
remove  bearings. 
ST2466M 
OVERHAUL I23  

1 37 MANUALGEARBOX DEFENDER 
NOTE: One bearing  cage is twisted  in 
A manufacture.  The twist  causes  the gear 
to  tilt  on  the  shaft  forcing  the gear  into 
engagement.  Renew bearings  if worn  or if the 
gear  jumps  out of engagement. 
2. Fit  the  bearings  either way round  and secure 
with  the  circlip. 
3. Check  condition  of  idler  gear and mating teeth 
on  layshaft  and synchromesh  outer member. 
ST2447M 
p v . ; SELECTORS 
1. Examine  selector  rail  and pins  for wear  and...

LT77S MANUAL GEARBOX 
.. A 
Assembling  selectors. ASSEMBLING GEARBOX SHAFTS TO CENTRE 
PLATE 
Fitting gears to centre  plate 
7. Rest first-second  fork and shaft assembly on 
bench  and locate  pin in jaw  of fork. 
8. Fit interlock  spool  and third-fourth  fork  and 
engage 
spool in jaw  of fork. 1. Secure centre  plate to workstand, fit bearing 
tracks  and inboard detent  ball and spring. 
8 7 
ST2-M 
9. Slide spool and fork  towards first- second 
selector  until 
slot in spool locates  over  pin...

137 MANUALGEARBOX DEFENDER 
4. Fit layshaft While  lifting  mainshaft to  clear 
layshaft  rear bearing. 
5. Turn selector  shaft and interlock  spool to allow 
reverse  lever  to  engage  spool  flange. 
6. Fit reverse  lever to pivot post  and secure  with 
pin and  circlip. 
7. Fit slipper  pad to lever. 
8. Fit reverse  gear  shaft,  spacer  and gear. 
9. Fit slipper to reverse  gear and ensure roll pin in 
shaft  engages 
in slot  in centre  plate. 
9 I .rU 
I 
I 
I ST3239M 
10. Secure reverse shaft...