Land Rover Defender 90 110 Lt77s Workshop Supplement Rover Manual

LT77S MANUAL GEARBOX 
.. .. 
DATA 
Reverse  lever and  slipper  pad clearance .......................... 0,725 mm 
Reverse gear plunger  operating load ................................ 45 to 55 kg 
Synchromesh  assemblies  push through load ................_... 8,2 to 10 kgf 
Clearance  between  baulk rings and gears 
........................ 0,38 mm 
Fifth gear  end float ............................................................ 0,020 mm 
Third  gear end float...

LT77S MANUAL GEARBOX 
SERVICE TOOLS 
SERVICE TOOLS 
NOTE: Where the use  of special  tools is 
specified,  only these  tools should  be 
used  to avoid  the possibility  of personal 
injury  and or damage  to components. 
1 
18G  705  Puller, bearing remover 
8G  705
-1A  Adaptor for  mainshaft oil seal 
track  and layshaft fifth  gear 
ia~.705- 
0 
8G  705-7 
Adaptor for layshaft bearings  18G  1400 
Remover  synchromesh  hub and 
gear  cluster 
-. __ 18G.7400-1 
8G 1400-1 Adaptor  mainshaft fifth  gear...

37 MANUAL GEARBOX DEFENDER 
18G.47BAX 
18G 47BAX Conversion kit 
18G  284  Impulse extractor 
18G284AAH 
8G 284AAH Adaptor for  input shaft pilot 
bearing track 
8G 
1422 Mainshaft rear  oil  seal replacer 
18G.1431 
18G 1431 Mainshaft rear oil seal replacer 
18G1205 
18G 1205 Flange holder 
2 I SERVICETOOLS  

LT77S MANUAL GEARBOX 
 . .. -- 
LOCALLY  MANUFACTURED TOOLS 
In addition  to the  special service tools, the  following 
tools  can be locally made 
to assist the  dismantling 
and  assembly  of the  gearbox.  The following  overhaul 
procedure  is  based upon  the assumption  that these 
tools are available. 
Tool A. Dual purpose  tool. Reverse shaft  retainer to 
prevent  the  shaft falling  out when  the  gearbox in 
inverted.  Also,  a layshaft fifth  gear retainer to  hold 
the  fifth  gear  whilst...

137 MANUALGEARBOX DEFENDER 
Tool E. Workstand  for  securely  locating the  gearbox 
during overhaul.  Manufacture from 
30 x 30 
angle iron.  The  single  hole marked A should  be 
drilled  through  the  material with  a 
10 drill.  The  four counter 
sunk blind holes  marked 
B should 
also  be made with  a 
lOmm drill,  but  must not  be 
drilled through 
the material. 
ST2153M 
1 52mm I I 64mm I 
80mm 
1 Omm 
228 + 
I 
I I 
+ 
I I I 
4 
SERVICE TOOLS  

.. . I. ... . . .I ., .. I:. ,: ... ,. . . . ... , ! :: *,;A. 
. ... .. 
, .. , ., 
SERVICE TOOLS 
LT77S MANUAL GEARBOX 
5 
GEARS AND SHAFTS 52. 
1. 
2. 
3. 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
12. 
13. 
14. 
15. 
16. 
17. 
18. 
19. 
20. 
21. 
22. 
23. 
24. 
25.  26. 
27. 
28. 
29. 
30. 
31. 
32. 
33. 
34. 
35. 
36. 
37. 
38. 
39. 
40. 
41. 
42. 
43. 
44. 
45. 
46. 
47. 
48. 
49. 
50. 
51. 
Third - fourth  selector fork. 53. 
Interlock spool.  54. 
First 
- second  fork  and  selector  rail assembly. 55....

I 
I 37 MANUALGEARBOX DEFENDER 
Si3281 M 
SERVICE TOOLS  

LT77S MANUAL GEARBOX 
rc .. , ,U, 
GEARBOX CASING 
. 
1. Front cover. 
2. Front cover oil seal. 
3. Front cover  gasket. 
4.  Oil drain  plug  and washer. 
5. Oil level  plug. 
6. Gearbox main casing. 
7. Spool retainer. 
8. Gasket. 
9. Inboard detent  ball and  spring. 
10. Reverse  lever  and slipper. 
11.  Locating dowels 
- centre  plate to maincase. 
12.  Reverse  lever  pivot 
post. 
13. Centre  plate.  14. 
Selector  plug, detent  ball and spring. 
15. Gasket. 
16. Fifth gear  selector bracket....