Land Rover Defender 90 110 Lt77s Workshop Supplement Rover Manual

							.- -... . ..1. ..~. . ,. I. ._ . , ..:.:: . . .. 
425DDEFENDER 
90.110 130 
DEFENDER 
LT77S GEARBOX 
WORKSHOP  MANUAL SUPPLEMENT 
Publication  Number SLR 621 EN WS  2 
1, 
Published  by the 
Technical  Publications  Department 
of 
Land Rover 
Lode  Lane 
Solihull 
West  Midlands,  892 8NW 
England 
@ Copyright  Land Rover  1991  
						

							37 . MANUAL GEARBOX 
..... ...... ..... ..... .... ..... .*. . ....)I .... 
CONTENTS 
Page 
OVERHAUL 
DISMANTLE ........................................................................\
............................. 1 
GEAR SELECTOR  HOUSING ........................................................................\
.. 1 
EXTENSION  HOUSING ........................................................................\
............ 2 
MAINSHAFT AND LAYSHAFT  FIFTH GEARS .................................................. 3 
REVERSE  SHAFT, LAYSHAFT  AND MAINSHAFT 
........................................... 5 
DISMANTLE  MAINSHAFT ........................................................................\
........ 7 
GEARBOX CASINGS AND OIL PUMP ............................................................. 8 
GEAR  CHANGE  HOUSING ........................................................................\
.... 10 
GEAR SELECTOR  HOUSING ........................................................................\
 12 
SYNCHROMESH  ASSEMBLIES .................................................................... 15 
CHECKING BAULK RING CLEARANCES ...................................................... 17 
INPUT  SHAFT ........................................................................\
........................ 18 
MAINSHAFT ........................................................................\
........................... 18 
MAINSHAFT  GEAR END FLOAT  CHECKS .................................................... 19 
ASSEMBLING  MAINSHAFT ........................................................................\
... 21 
LAYSHAFT 
........................................................................\
............................. 23 
REVERSE  GEAR AND SHAFT 
...................................................................... 23 
SELECTORS 
........................................................................\
.......................... 24 
ASSEMBLING  GEARBOX SHAFTS TO CENTRE  PLATE 
.............................. 25 
FITTING  GEARBOX  CASING 
........................................................................\
. 27 
FITTING  FIFTH GEAR 
........................................................................\
............ 28 
FIFTH GEAR  SELECTOR  FORK ASSEMBLY ................................................ 30 
EXTENSION  CASE 
........................................................................\
................ 31 
INPUT
-MAINSHAFT  BEARING ADJUSTMENT .............................................. 32 
LAYSHAFT  BEARING ADJUSTMENT 
............................................................ 32 
GEAR  LEVER  AND REMOTE  HOUSING  ASSEMBLY 
................................... 33 
BELL  HOUSING 
- FOUR  CYLINDER  ENGINE ............................................... 35 
BELL  HOUSING 
- V8 ENGINE ....................................................................... \
35 
SPECIFICATIONS.  TORQUE 
DATA ........................................................................\
....................................... 1 
TORQUE VALUES ........................................................................\
................... 1 
SERVICE TOOLS 
SERVICE  TOOLS ........................................................................\
..................... 1  
						

							~~ 
~ 37 - MANUAL GEARBOX 
CONTENTS 
Page 
LOCALLY 
MANUFACTURED  TOOLS .............................................................. 3 
GEARS AND SHAFTS ........................................................................\
............. 5 
GEARBOX CASING ........................................................................\
................. 7  
						

							LT77S MANUAL GEARBOX 
- I. 2 I. r DISMANTLE 
Bell housing 
- four  cylinder  engine 
1. Remove transfer  box, drain oil and clean 
exterior. 
2. If fitted,  clutch  release bearing clip. 
3. Remove  clutch release assembly. 
4. Remove one  pivot post  bolt,  slacken  the other 
and  move  post aside. 
5. Remove six bolts  and  withdraw bell  housing. GEAR SELECTOR HOUSING 
1. Remove four bolts  and remove  main  gearbox 
selector  housing. 
2. Remove transfer  box housing. 
3. Remove remaining bolts  and remove  remote 
housing. 
Bell housing - V8 engine 
1. Remove  clutch release bearing. 
2. Remove  screw and  spring clip and  remove 
release lever. 
3. Remove C clip  from  pivot  post. 
4. Remove  six bolts  and bell housing.  
						

							I 37 MANUALGEARBOX DEFENDER 
4. Drive out quadrant roll pin. 
5. Move  selector  shaft forward  to remove 
quadrant. 
n 
5 
ST2180M 
2. Using  service tool 18G 705 and 18G 705-1A 
withdraw  the  oil  seal collar. 
&- 
/U 
18G 705 
3. Remove  the  fifth gear extension  housing. 
4. Secure  the  centre  plate to the  gearcase  with 
EXTENSION HOUSING . two 8 x 35 bolts. 
1. Remove  snap ring retaining  oil  seal collar. 
ST2316M 
2 I OVERHAUL  
						

							.. ~$ :. .: .: I.. r. ~. ., 
LT77S MANUAL GEARBOX 
.. .. 
MAINSHAFT AND LAYSHAFT  FIFTH GEARS 
1. Remove mainshaft 0 ring. 
2. Remove oil pump drive  shaft. 
3. Remove E clips from selector fork. 
4. Remove fifth  gear selector Spool. 
5. Remove  selector fork bracket. 
9. Remove circlip retaining mainshaft  fifth gear 
synchromesh. 
10. Fit special tool 18G 1400-1 and 18G 1400 as 
illustrated.  
						

							137 MANUALGEARBOX DEFENDER 
11. Remove fifth gear synchromesh. I1 
-. i ST2296M 3. Invert  gear case  and locate  studs  in workstand - 
holes. 
12. Remove  layshaft fifth gear using special  tools 4. Remove selector  shaft spool  retainer. 
18G 
705 and  18G 705-1A. 
18G705-1A 
Main  gear case. 
1. Secure reverse  shaft  retainer,  manufactured 
tool A; to centre  plate. 
2. Fit studs, manufactured toolB to  gear  case. 
4 1 OVERHAUL  
						

							LT77S MANUAL GEARBOX 
5. Remove front cover  and gasket. 
6. Retrieve selective  washers. 
REVERSE SHAFT, LAYSHAFT AND MAINSHAFT 
1. Remove  retainer (tool A) and reverse  shaft. 
2. Remove thrust washer,  reverse gear and 
spacer. 
3. Remove reverse lever  pin  with E clip 
attached. 
4. Remove lever and slipper  pad. 
7. Remove bolts and lift-off  gear case. 
8. Secure centre plate with nut and bolt. 
ST23OlM Yt II I  
						

							I 37 MANUALGEARBOX DEFENDER 
5. Remove input shaft  and fourth  gear baulk  ring. 
6. Remove  layshaft by  tilting,  as illustrated and 
lifting  mainshaft. 
5 
ST 
I ST3245 M U 
7. Unscrew  plug and remove spring and outboard 
detent  ball. 
8. Align fifth gear  selector  pin with  centre  plate 
slot. 
9. Remove  mainshaft, gears,  selectors and forks. 
10. Remove selector fork  assembly from  gears. 
11. Collect  inboard detent  ball and spring  from 
centre  plate.