Land Rover Defender 90 110 Lt77s Workshop Supplement Rover Manual
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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 threads and with two 8 x 35 bolts. fit spool retainer. ST2515M CAUTION:,Do not use force to fit retainer. A Provided the spool has not been disturbed the retainer will slide into position. If not, remove the gear case and reposition spool or shaft. 7. Remove detent plug, apply Loctite 290 or Hylomar PL 32 to thread, refit and stake. 8. Fit layshaft and input shaft bearing tracks.
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 bolts. Insert disc between plate and layshaft. - 2. Release and invert gearbox and remove reverse shaft retainer plate. 3. With the extraction groove uppermost, drive fifth gear on to layshaft using 18G 1422. I, I ST2519M I 28 I OVERHAUL
;:::-: !::. ,::.q ... .. . . . ... I .., ~.I, ... .. 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 circlip. 8. Measure clearance between circlip and washer, 9. Tighten layshaft stake nut using 18G 1205. CAUTION: The practice of locking gears not acceptable due to high torque figure A to provide a restraint to tighten the nut is required. NOTE: Only limited movement of the synchromesh inner member on the main -shaft is permissable. The maximum clearance is 0,005 to 0,055mm (0.0002in) to (0.002in and to achieve this the following selective washers are available.
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 fitting pins and clips cover holes in centre plate to prevent them falling into casing. A 5. Engage tongue of spool in selector fork. 6. Fit oil pump drive to layshaft.
. -. . .. ,~. :, .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 groove. ST ST2512M d 4. Fit 0 ring collar to mainshaft using 18G 1431 4. 3221 M U 7 OVERHAUL ~ I31
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 clearance between front cover and gearcase with two feeler gauges. ST3269M 5. If required, change the selective washer to provide a clearance of 0,35mm to 0,085 (0.001 to O.OO3ins) less than the gasket thickness. NOTE: This will ensure that when the gasket and cover is fitted to the correct torque, the input and mainshaft bearings will have no pre -load and.not more than 0,06mm (0.0025in) end float. 6. Remove front cover and keep gasket and selective washer together. rj I, Mainshaft selective washers Part number Thickness() FRC 4327 FRC 4329 FRC 4331 FRC 4333 FRC 4335 FRC 4337 FRC 4339 FRC 4341 FRC 4343 FRC 4345 FRC 4347 FRC 4349 FRC 4351 FRC 4353 FRC 4355 FRC 4357 FRC 4359 FRC 4361 FRC 4363 FRC 4365 FRC 4367 FRC 4369 131 137 !,63 1,69 1,75 1,81 1,87 1,93 1,99 2,05 2,ll 2,17 2,23 2,29 2.35 2,41 2,47 2,53 2,59 2,65 2,67 2,77 LAYSHAFT BEARING ADJUSTMENT 1. 2. Place original selective washer on layshaft bearing, fit front cover without gasket, and finger tighten bolts. Measure clearance, with two feeler gauges, between cover and gearcase. Select a shim that will provide a clearance equal to the thickness of the gasket that was selected and measured when calculating the adjustment of the input and mainshaft bearing. .. ST2503M 11 32 I OVERHAUL
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 towards gearcase. 4. Fit mainshaft and layshaft selected washers and gasket. a 4 ST2521M U 5. Wrap protective tape round input shaft splines. 6. Apply Hylomar PL 32 to bolt threads and secure cover. Layshaft selective washers. Part number FTC 0262 FTC 0264 FTC 0266 FTC 0268 FTC 0270 FTC 0272 FTC 0274 FTC 0276 FTC 0278 FTC 0280 FTC 0282 FTC 0284 FTC 0286 FTC 0288 FTC 0290 FTC 0292 FTC 0294 FTC 0296 Thickness() 1,36 1,42 1,48 134 1,60 1,66 1,72 1,78 1,84 1,90 1,96 2,02 2,08 2,14 2,20 2,26 2,32 2,38 2. With a new gasket, fit remote housing locating over dowels. NOTE: Ensure rollers locate in quadrant a fork. 3. Fit transfer gear change housing. Reverse gear plunger adjustment. 1. Fit plunger with original shims and tighten bolts. 2. Slacken locknut, turn adjuster screw so that dimension A is approximately 12 mm (0.50 in). Tighten locknut. ----- A-(- ST3223M /
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 NOTE: The purpose of this adjustment is A to set both bolts so that the bias spring legs apply equal pressure on both ends of the gear lever cross pin when third or fourth gear is engaged. This will ensure that when the lever is in neutral, the gear change mechanism is automatically aligned for third or fourth gear selection. 1. Select fourth gear and lift both spring legs over the cross pins. 2. Turn adjustment bolts until heads touch spring legs. 3. Apply light pressure to gear lever to the right and adjust left hand bolt. ,jy 4% $-: NOTE: Clearance between spring leg and bolt 0,05 mm (0.002 in.) using feeler gauge. 2. Select fifth gear. While applying light pressure to gear lever towards right, turn screw clockwise until it contacts yoke. Turn screw half a turn anti- clockwise and tighten nut. ST2198M 4. Move lever to left and adjust right hand bolt to clearance. 5. Tighten locknuts.
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 pivot post. 5. Fit staple to release assembly, short leg to lever. NOTE: The staple is an aid to assembly only which may become dislodged or lost in service without detriment. NOTE: Fit the 12 x 45 bolts through dowels and 12 x 30 bolts in remaining positions. 2. Apply molybdenum disulphide grease to pivot post, release lever, socket and push rod. Not the bearing guide. 3. Fit C washer to pivot post. 4. Fit spring clip to lever and fit lever to pivot post. NOTE: Position spring clip behind C washer and tighten screw. 5. Fit bearing and retain with plastic staple. ST2202M 4 4 4 L ST3286M