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 journals  for  wear and scores. 
2. Check  condition of circlip  grooves. 
3. Examine splines  for wear  and damage. 
4. Use an  air line to check  that  the  main  oil feed 
from  the  pump  is clear  and  feed 
to spigot 
bearing. 
5. Check  oil  feed holes to  roller  bearings  are clear. 
3 
.. ..-. . - -\~ .?. :c , t . :., _r 
5. Support  the  shaft  under MS 47 and  press in a 
new track. 
ST3241 M  
						

							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 (0.008in). 
ST3235M 
ST3251 M 
Second  gear end-float. 
First gear bush  end-float. 
1. Fit needle  roller and  second gear 
2. Fit third  gear bush. 
3. Check  clearance  between  second gear  and 
bush flange. 
Not to exceed 0,20 (0.008in). 
4. Remove  above components. 
1. Invert mainshaft  rear end uppermost. 
2. Fit inner  and outer  second  gear baulk  rings. 
ST3252M  I\ 
OVERHAUL 1 19  
						

							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 gear  bush 
Part number  Thickness 
FTC2005 
FTC2006 
FTC2007 
FTC2008 
FTC2009 
30,905/30,955 
30,955131,005 
31,005131,055 
31,055/31,105 
31 , 1 05/31 ,155 
Check first gear  to bush  end-float. 
1. 
Fit roller  bearing and  bush to first  gear. 
2.  Place bush flange  side downwards  on  a  raised 
block  on a flat  surface. 
NOTE: the  block  should  be approximately 
the  same  diameter  as the  bush  flange 
so 
that the gear  is suspended  and does  not 
rest 
on the  flat surface.  
						

							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 adaptor 18G 47 BAX. 
ST3262M (. 
MS47- 
OVERHAUL 121  
						

							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 is necessary  since it 
is  probable  that when  pressing  on the 
bearing  it will  have  clamped  the first  gear 
bush  preventing 
it from turning. 
6. Reposition mainshaft in vice  and  using a  screw 
driver  blade check  that the  first  gear bush  is 
free  to turn. 
6’ 
ST3256M 
ST3233M 
Third-fourth  synchomesh  assembly 
22 I OVERHAUL  
						

							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 
damage. 
2. Examine  first-second selector  fork for wear 
cracks  and damage. 
NOTE: The  the selector  rail and  fork is 
only  supplied  as a complete  assembly. 
3. Examine third-fourth  selector  fork for wear, 
cracks and  damage. 
4. Examine fifth gear  selector  fork,  pads and pivot 
pins. 
5. Examine  interlock  spools for  wear and damage. 
1 
ST2482M 4 
6. Renew  retaining circlips if distorted. 
I ! . .. . .. ... .... .: . *i 
4. Examine  idler  shaft  for  wear. scores  and oittina.  
						

							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 
keeping the 
spool engaged in third-fourth  fork 
jaw. 
J 
ST2487M 
ST3282M I 
2. Check  both synchromesh units  are  in neutral 
and 
fit selector  shaft assembly. 
3. Fit mainshaft  and selectors to centre  plate and 
align  pin with 
slot in plate.  
						

							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 with manufactured  tool 
A. 
11. Fit  reverse gear thrust  washer  to shaft. 
12. Fit fourth  gear baulk  ring. 
13. Lubricate  spigot bearing  and fit input  shaft. 
14. Remove  centre  plate workstand bolt and fit 
gasket. 
-1 ST3267M 
10 R8 
ST2492M II 
26 I OVERHAUL