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  assembly. 
4 
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							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  all components  and discard 
gaskets  and seals. 
Gearbox  casing 
1. Remove mainshaft  and layshaft  bearing tracks. 
2. Remove  plastic scoop from  inside the  casing. 
3. Inspect case  for  damage, cracks and stripped 
threads. 
4. Fit  a new  scoop  with  scoop  side towards top  of 
casing. 
Front  cover 
1. Remove  oil  seal from  cover. Do not fit  a  new 
seal  at this  stage 
ST3234M  
						

							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 abestos. 
INTRODUCTION, Information,  Poisonous 
A Do not attempt to clean  it. see 
substances. 
7. Fit new  bush with  drain holes towards bottom of 
casing. 
CAUTION:  If drain  holes  are not 
positioned  correctly oil may  build  up 
behind  oil seal  and cause  a leak. 
A 
ST3238M 
Extension  case 
1. Examine for damage to threads and  machined 
faces. 
2. Remove oil  pump cover,  inspect  gears  and 
housing and renew  if required. 
8. If extension  housing  is being renewed transfer 
grub  screw 
to new  housing.  Apply Loctite to 
threads. 
ST3218M  
						

							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. 
WARNING:  Hold the nylon  spring  loaded 
causing  personal injury. 
A pad while  removing  the lever to prevent it 
6. Remove  gear selector  housing from  remote 
housing. 
10 I OVERHAUL  
						

							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 .: , 
2. Remove  circlip to release seating from  trunnion. 
3. Remove fifth  gear locknut  and stud. 
4. Remove  reverse gear  plunger  and  shim. 
I 
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ST2183M 
5. Remove fifth  gear spool  guide. 
6. Remove  blanking  plug. 
7. Drift-out roll pin  securing  quadrant to shaft. 
8. With selector thr~ugh hole. 
9. Remove  selector  shaft 0 ring. 
10. Remove circlip to  release rollers and pin from 
quadrant. 
ST3274M U 
11. Clean  and examine all  components  and renew 
12. Assemble  housing by  first fitting 0 ring to 
13. Fit quadrant  and secure  with  roll pin. 
14. Fit rollers and  secure with  circlip. 
15. Fit fifth  gear  spool retainer  and  apply Loctite 
16.  Apply  Loctite 
290 to reverse  switch threads. 
17. Fit seating to trunnion and secure with  circlip. 
18. Fit trunnion to shaft  and apply  Loctite  to 
19.  Fit reverse  gear plunger  and original shims. 
20. Fit fifth  gear stud stop  and locknut. 
21. Fit  new  bucket plug with  Hylomar PL 32. 
22. Fit gear  selector  housing  to remote  housing. 
where 
necessary. 
shaft. 
290 to bolt threads. 
retaining screw threads.  
						

							1 DEFENDER 
37 MANUAL GEARBOX - 
(, . 
I 
1.: 
-_ 
GEAR SELECTOR  HOUSING 
t I 
0,: 
i/ 
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 
assembly. 
2. Disconnect the  gear  lever from  selector  fork. 
3. Retrieve the  non metallic  bushes. 
4. Remove circlip to release ball and seat  and 
withdraw  gear  lever. 
5. Remove  screws  from  end cover to withdraw 
cover  and  cross shaft. 
6. Remove  selector  fork. 
7. Remove  detent  spring  and plate. 
8. Clean and examine  ail  parts  and renew where 
necessary. 
NOTE: Assemble  the housing  using 
A mutti-purpose grease on all moving parts. 
9. Fit internal  and external 0 rings  to fork 
assembly. 
10. Fit detent  spring. 
11.  Fit 
0 rings to end cover  and  fit to short  end 
of  cross  shaft. 
12.  Insert shaft  into fork  and secure  end  cover  with 
screws. 
13. Fit  Nylon seat, groove downwards,  to gear 
lever. 
14. Fit gear  lever and  seat  to  cross shaft and 
secure with  circlip. 
15.  Fit  bushes 
to gear lever and  secure with clevis 
pin and  split  pin.  
						

							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 mainshaft splines.  (except fifth 
gear  synchromesh). 
6. Examine inner and  outer splines for  wear. 
ST2803M 
7. Examine the dog  teeth  on all gears for wear and 
damage. 
NOTE: exampleA shows  a tooth in 
a good condition. Example6 shows the 
rounded corners  of a worn  tooth. 
SR449M U 
OVERHAUL I 15  
						

							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  spring  each 
side of the  synchromesh. 
NOTE:  The hooked  end of each  spring 
must  locate  in the  same  slipper  with the 
free  ends  running 
in opposite  directions 
and resting against  the remaining  slippers. 
ST2467M 
13. Assemble third-fourth  and fifth gear 
synchromesh  components  as in instruction 
12. 
NOTE:  The back  plate  for fifth  gear  is 
fitted  to the  rear  of the  assembly  with the 
single  tag locating 
in a slot  in the  inner 
member. 
11 
ST3247M ST3276M 
16 1 OVERHAUL