Land Rover Defender 90 110 Lt77s Workshop Supplement Rover Manual

LT77S MANUAL GEARBOX 
OVERHAUL 
2 >- 
I : FITTING GEARBOX  CASING 
27 
1. Turn selector  shaft and spool to neutral 
2. Fit out-board  detent  ball and sprlng and secure 
position. 
with  plug. 
ST2494M 
2 
3. Fit guide  studs  to casing and check oil scoop IS 
4. Without  using force,  fit gearcase. 
correctly 
fitted. 
NOTE: Ensure  that the centre  plate 
dowels  and selector  shaft are properly 
located. 
5. Secure centre  plate and gearcase to  workstand 
6. Apply  PL 32 to joint  face and bolt...

137 MANUALGEARBOX DEFENDER 
6% ; FITTING FIFTH GEAR 
A 
to the  layshaft  front bearing. ToolDand 
packing  disc should  be made  to the  dimensions 
given 
to absorb the force.  The plate  also retains 
the  input  shaft bearing  outer track. 
4. Fit a new  stake  nut but do  not tighten. 
5. Fit fifth gear  assembly to  mainshaft. 
CAUTION: Since  the fifth  gear  is a tight 
fit  on 
the layshaft,  the force,  when 
pressing  the gear,  must not be transfered 
1. Secure  the plate with  two 8x25...

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LT77S MANUAL GEARBOX 
6. Press fifth gear  synchromesh  assembly to 
mainshaft using 18G 1431. 
CAUTION:  Before pressing  the assembly 
locate 
in the  baulk  ring slots. 
A fully  home,  ensure  that the slipper  pads  Part 
number  Thickness 
FRC 
5284 
FRC 5286 
FRC 5288 
FRC 5290 
FRC 5292 
FRC 5294 
FRC 5296 
FRC 5298 
FRC 5300 
FRC 5302 
5,lO 
5,16 
5,22 
5,58 
5,34 
5,40 
5,46 
5,52 
558 
5.64 
7. Fit  the  thinnest  washer and secure  with...

1-37 MANUAL GEARBOX  DEFENDER 
10. Secure tool A to gear  and  gear case and 
using  a  suitable torque  wrench  tighten the  nut 
to the correct  torque. 
FIFTH GEAR SELECTOR FORK ASSEMBLY 
1. Fit fifth  gear  selector  fork bracket. 
2. Fit the  fifth  gear spool long  end towards  centre 
plate. 
11. Using  a round nose  punch,  form  the collar  into 
the  layshaft 
slots. 
3. Fit  slippers  to selector  fork. 
4. Fit  fork  to  synchromesh  and secure  with  pins 
and 
E clips. 
NOTE:  Before...

. -. . .. ,~. :, .f. . .... , .. .. . .. . ,.. 
LT77S MANUAL GEARBOX 
EXTENSION CASE 
1. Release  centre plate from workstand  and fit 
gasket on joint  face. 
2. Fit extension  case while aligning oil pick-up 
pipe. Remove guide studs and  secure  to main 
case. 
NOTE: Do not  use  force,  if necessary 
remove  case and re
-align  oil pump  drive 
if case does  not fit first  time. 
CAUTION:  To protect 
0 ring  while 
A fitting,  cover mainshaft  splines with 
smooth  tape. 
3. Fit 0 ring to mainshaft...

137 MANUALGEARBOX DEFENDER 
INPUT-MAINSHAFT BEARING ADJUSTMENT 
1. Turn  gearbox  over with  input shaft  uppermost. 
Remove  layshaft support  plate. 
NOTE:  Correct  shimming  of the 
input 
shaft  bearing  is vital  to ensure  that the 
mainshaft  assembly has the design 0 
intended  end float,  and the bearings  are not 
pre
-loaded. 
2. Measure the  thickness  of a new  front  cover 
gasket. 
3. Place the  original  shim on mainshaft bearing 
and finger  tighten  the  bolts. 
4. Measure the...

LT77S MANUAL GEARBOX 
A. .. 
NOTE: This will ensure  zero layshaft 
0,025 (0.001 in) pre-load  once  the  GEAR 
LEVER  AND  REMOTE  HOUSING 
a bearing end float and not more  than  ASSEMBLY 
cover 
and gasket  are fitted  and bolts  correctly 
torqued. 
1. Fit quadrant to selector  shaft  with  new roll  pin. 
NOTE:  Push shaft forward,  fit quadrant 
so ledge is to the  left viewing box from 
rear.  Return  shaft to neutral  position. 
3. 
Remove cover  and selected washer  and fit  new oil seal, lip...

137 MANUALGEARBOX DEFENDER 
NOTE: 
If necessary,  final adjustment  can 
be  made 
in vehicle.  To increase pull-over 
load  turn screw  clockwise or 
anti-clockwise  to reduce  load. 
Fifth  gear stop  screw  adjustment. 
1. Adjust  screw  to  protrude from housing  the 
distance  across  corners 
of locknut. 
NOTE:  This is only  an approximate 
setting  which will limit  travel  of selector 
yoke  but will  allow  fifth gear  to be 
selected. 
/------ // 
LA 
ST3225M 
L I 
Bias  spring  adjustment...

LT77S 
I 8: i .. ,I BELL HOUSING - FOUR  CYLINDER  ENGINE 
MANUAL GEARBOX 
BELL HOUSING - V8 ENGINE 
1. Fit bellhousing  locating  over hollow dowels and 
secure  with bolts. 1. Fit bell  housing  locating on hollow dowels. 
NOTE:  Fit the 
12 x 45 mm bolts  through 
dowels  and 
12 x 30 mm bolts in 
remaining  positions. 
2. Secure  pivot  post. 
3. Apply  molybdenum  disulphide grease  to pivot 
post,  lever  pads  and pins. 
4. Assemble  pads  to  lever and lever to  bearing 
and  fit assembly  to...