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 .......................................................... 0,020 mm 
Second  gear end float ...................................................... 0,020 mm 
First gear  bush  end float ................................................... 0,075 mm 
First gear end float ............................................................ 0,20 mm 
Fifth gear  synchromesh  end float ...................................... 0,005 to 0,055 mm 
TORQUE VALUES 
NOTE: Torque  wrenches  should be 
regularly  checked for accuracy  to ensure 
that 
all fixings  are tightened  to the A 
correct  torque. 
Oil pump to extension case 
Clip clutch  release lever 
Spool  retainer 
to gearcase 
Spool  guide 
to remote housing 
Extension case  to gearcase 
Pivot plate,  clutch  release 
Remote  housing 
to gearcase 
Gear  lever  housing 
to remote housing 
Guide,  clutch release sleeve 
Slave  cylinder 
to bell housing 
Front cover  to gearcase 
Fifth  gear  support  bracket 
bolts 
Plunger housing  to remote housing 
Gear  lever  retainer 
Lower gear  lever 
to extension nut 
Reverse  lever  pivot  post  nut 
Clutch  housing 
to gearbox  bolts 
Plug, detent  spring  and ball 
Oil drain  plug 
Oil filter  plug 
Oil filler 
- level plug 
Breather 
Fifth  gear  layshaft  stake nut 
Bottom cover 
to clutch  housing 
Nm 
7- 10 
7 - 10 
7 - 10 
7- 10 
7- 10 
22 - 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
7 - 10 
40 - 47 
22 
- 28 
65 - 80 
22 
- 28 
47 - 54 
65 - 80 
25 
- 35 
14 - 16 
204 - 231 
7- 10 
SPECIFICATIONS, TORQUE  
						

							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 
MS47 
1s 47 Hand press 
186.47BA 
8G 47BA Adaptor  input shaft  bearing  
						

							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  releasing stake nut.  Use  5mm 
mild  steel  to manufacture  the tool.  When  using the 
tool for the  layshaft nut,  a suitable spacer  is  required 
20 diameter 23 long, with  an 8mm  diameter 
clearance  hole. 
Tool B. Four  pilot studs  with  an 8mm thread for 
locating  in the  four  counter  sunk blind holes 
in the 
workstand. 
B 
ST 21 55M . 
Tool C. Mild steel dummy  centre bearing for  the 
selection  of first  gear  bush. 
C 
53.0 
A -+ 0.10 
+ 0.005 - 0-000 
ST2 15 4M 
Tool D. Layshaft  support  plate is fitted  with  two  8 x 
25 bolts and washers  to the  front  of  the  gearbox 
case. 
It also  supports the  input  shaft bearing outer 
track. 
D 
ST1118M 
SERVICE TOOLS  
						

							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. 
First - second synchromesh.  56. 
First  gear  synchromesh  outer baulk  ring.  57. 
First  gear  synchromesh  inner  baulk ring.  58. 
Cone. 
Thrust  washer. 
First  gear. 
Needle roller  bearings. 
First  gear  selective  bush. 
Centre taper  roller  bearing. 
Circlip. 
Thrust washer. 
Fifth  gear. 
Fifth  gear  baulk  ring. 
Fifth  gear  synchromesh. 
Fifth  gear  synchromesh  back plate. 
Fifth  gear  synchromesh  selective  washer. 
Circlip. 
0 ring. 
Oil seal  collar. 
Snap  ring. 
Fourth gear baulk  ring. 
Pilot taper  bearing. 
Spacer. 
Third 
- fourth  synchromesh. 
Third  gear baulk  ring. 
Third  gear. 
Third  gear bush. 
Second  gear. 
Thrust  washer. 
Cone. 
Second gear  synchromesh inner  baulk ring. 
Second  gear  synchromesh outer  baulk ring. 
Mainshaft. 
Input shaft bearing track  and selective  washer. 
Input shaft. 
Input shaft taper  bearing. 
Fourth gear. 
Selective  shim. 
Taper  bearing. 
Layshaft  fourth gear. 
Layshaft  third gear. 
Layshaft  second gear. 
Layshaft  reverse gear. 
Layshaft first  gear. 
Taper  bearing.  Layshaft fifth  gear. 
Layshaft iifih gear  retaining stake  nut. 
Circlips  retaining first  gear and first
-second  gear 
synchromesh.  Snap 
ring  retaining second  gear cone  and 
spacer. 
Spacer. 
Snap  ring. 
Reverse idler  gear. 
Thrust  washer. 
Snap  ring. 
Fifth  gear 
spool.  
						

							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. 
17.  Fifth  gear  selector 
fork. 
18. Reverse  gear shaft. 
19.  Oil pick
-up pipe. 
20.  Oil  pump drive shaft. 
21. 
Oil pump  gears  and  cover. 
22.  Fifth gear  extension housing. 
23.  Fifth  gear  extension housing  drain plug and 
filter. 
24.  Ferrobestos  bush. 
25. Oil seal.  ~  ~~ 
SERVICE TOOLS