Land Rover Defender 90 110 Workshop 1984 Rover Manual

Always have a fire  extinguisher containing  FOAM CO2 GAS, or POWDER  close at hand when handling or draining 
fuel, 
or when  dismantling  fuel systems  and in areas where fuel  containers  are stored. 
Always  disconnect  the vehicle  battery BEFORE  carrying out dismantling 
or draining work on a fuel  system. 
Whenever 
petroVgasoline is  being  handled, draincd or stored,  or when fuel systems  are being  dismantled  all forms  of 
ignition must  be 
extinguishcd or  removed, any head-lamps  used...

. Special Service Tools 
The use of approvcd special scrvice tools is important. Thcy are essential if scrvicc opcrations arc 
to  be 
carricd out  cfficicntly,  and safely. The amount of timc which thcy save can be considcrable. 
Every  special tool is designcd with the closc co-operation of Land Rover Ltd.,  and no tool  is put 
into  production  which has 
not been tested  and  approvcd  by us.  New  tools are only  introduced 
wherc an operation cannot  be satisfactorily carried out using cxisting...

LT77 FIVE SPEED GEARBOX 1371 
-.x,,

1371 LT77 FIVE SPEED GEARBOX 
25. Remove  the three  nuts and bolts  securing  the transfer 
box  L.H.  and R.H.  mounting  brackets 
to the chassis. 
26.  Remove 
the nuts  retaining the brackets  to the 
mounting  rubbers and remove the brackets. 
27.  Lower  the hoist  sufficiently  to allow  the transfer 
lever  to clear  the transmission  tunnel aperture. 
28.  Disconnect 
the four-wheel  drive indicator  electrical 
lead  (bullet  connection). 
29.  Remove  the cleat  retaining  the reverse  light...

LT77 FIVE SPEED GEARBOX (37 I 
61. Fit the  handbrake cable using a new  split  pin to 
secure the  clevis pin. Grease  the clevis  and tighten 
the outer  cable lock nuts. 
62.  Connect the  speedometer  cable. 
63.  Check  that 
the three  drain plugs  are tight  and 
remove  the main  gearbox  and  transfer box filler 
level  plugs. 
Fill the main  gcarbox  with 
approximately 
1,76 litres (3 pints)  of a 
recommended oil or until it begins to run  out of the 
filler  level  hole. Fit  and  tighten...

171 LT77 FIVE SPEED GEARBOX 
ST542M 
11. Using  tools 186705  and 186705-1A remove the 
oil  seal  collar. 
/ 12 
ST543M 
12. Remove  the ten bolts  and spring  washers  securing 
the  rear  cover  to the  gearcase;  withdraw 
the rear 
cover  and discard  the gasket. 
13. 
Fit two  dummy  bolts (8 x 35 mm) to the  casing to 
retain  the centre  plate to the  main  case. 
14.  Remove  the oil seal  collar 
‘0’ ring  from  the 
mainshaft. 
15.  Withdraw  the 
oil pump drive shaft. 
16.  Remove  the two...

LT77 FIVE SPEED GEARBOX 
31. Remove the dummy  bolts and carefully lift the 
gearcase,  leaving the ccntre  plate and gear 
assemblies  in position.  Discard gasket. 
32.  Insert  two slave  bolts and nuts  to retain 
the centre 
plate 
to the  stand;  and remove the circlip,  pivot 
pin,  reverse  lever and slipper  pad. 
33. Slide the reverse  shaft rearwards  and lift off the 
thrust  washer,  reverse gear and reverse  gear 
spacer. 
34.  Lift 
off the layshaft  cluster. 
35. Remove  the input  shaft...

LT77 FIVE SPEED GEARBOX 
Mainshaft 
42. Remove the centre  bearing  circlip. 
43.  Using  press 
MS47 and  any suitable  metal  bar, 
remove  the  centre  bearing, first gear  bush,  first 
gear  and needle  bearings  and  first gear 
synchromesh  cone. 
Input shaft ST 
44. If a difficulty  is experienced in removing  the first 
and  second  gear synchromesh  hub, locate 
underneath 
the sccond  gcar with a suitablc  tool; 
and  extract  the  complete  synchromcsh hub and 
second  gear assemblies  using...

~~77 FIVE SPEED GEARBOX 137 I 
Gear selector  housing - Early models (Not illustrated) 3- - ;c ::: Centre  plate .&&L\.S v,, 62. Remove  the layshaft  and mainshaft  bearing tracks 
from  the centre  platc and reverse  pivot post. 
Main  gearbox  casing 
63. Remove  the mainshaft  and layshaft  bearing tracks 
64.  Remove  the plastic  oil trough  from 
thz front of 
from the main  casing. 
the casing. 
Selector  rail 
65. The  selector  rail is supplied  complete with first 
and  second  selector  fork,...

LT77 FIVE SPEED GEARBOX 
Fifth gear plunger  assembly - Early models  only 
81. Remove  the  plug,  long  spring  and detent  ball 
from  the 
fifth gear plunger. 
82.  Remove  the circlip  which  retains the 
fifth gear 
plunger,  pull out  plunger  and  short spring.  Keep 
all  parts  labelled  and separated  from the reverse 
 plungerassembly. 
82 
86. Inspect all gear teeth for chipped or broken teeth, 
or  showing  signs of excessive  wear. Inspect 
all 
spline  teeth  on  the  synchromesh...