Land Rover Defender 90 110 Workshop 1984 Rover Manual

LT 95 FOUR SPEED GEARBOX 1371 
OVERHAUL LT 95 FOUR SPEED GEARBOX 
The following  overhaul instructions  assume that the 
gearbox  is removed  from the vehicle  and the 
oil drained. 
Remove  the clutch  slave cylinder,  release mechanism 
and  bearing  assembly,  stand the gearbox  on a wood 
block  on the  bell  housing  end. 
REMOVE 
AND OVERHAUL  SPEEDOMETER 
DRIVE  HOUSING 
1. Remove the brake drum retaining  screws  and 
2. Remove the  four bolts retaining  back plate, 
withdraw 
the drum. 
remove...

LT 95 FOUR SPEED GEARBOX 
ST1204M I# 
Check differential  pre-load 
This  check  must be carried  out if a replacement 
speedometer  drive housing  is 
to be fitted. The check  is 
also  required 
if a replacement gcarbox,  differential unit 
or  diffcrcntial 
unit bearing  is being  fitted. 
17. 
18. 
19. 
20. 
21. 
22. 
- - 
Measure  and  record  the thickness  of the  new  joint 
washer  for the speedometer  drive housing. 
Offer  the 
spcedometer housing,  less joint washer. 
to  the  gearbox....

LT 95 FOUR SPEED GEARBOX 1371 
::‘:?2 REMOVE AND OVERHAUL  MAINSHAFT +:... ~. I TRANSFER GEAR 
Special  tool: 
lSC1388 - mainshaft  output gear puller 
y., .:, c .: 
1. Remove thc mainshaft  rear bearing  housing. 
2. Lift out the roller  bearing. 
3. Remove the snap-ring. 
4. Withdraw  the shim  washer. 
5. The transfer  gcar is retained  on  the  splines with 
Loctite  275. Use 
a puller  1861388 to  withdraw it. 
NOTE: The roller  bearing  outer race is located  by a roll 
pin  which must be...

LT 95 FOUR SPEED GEARBOX 
-_ I 
ST12 1 OM 
14. Position a thrust bearing  washer on the  ‘high’  gear. 
15. Fit a spacer, nccdlc-roller bearing  and a further 
spacer  to the  input  gear inner 
member. 
16. Position the assembled  input gear on the  shaft  and 
engage  the  lower spacer 
in the previously 
positioned  thrust  bearing 
washcr. 
17. Locatc  a thrust  bearing  washer over thc upper 
spacer. 
18. Fit  a needle  roller bearing  and the ‘low’  gear (plain 
side  last) 
to the shaft. 
19. 
Fit...

. .c. .. .. , ..*. .,? .ti .? .. .. ... ..: 
LT 95 FOUR SPEED  GEARBOX 
REMOVE  AND OVERHAUL  DIFFERENTIAL  UNIT 
Special  tool: 
18G47BB -bearing  extractor 
1. Select the differential lock. 
2. Rcmove the differential  lock actuator  assembly 
3. Remove  the front output shaft and  housing. 
4. Remove  the speedometer  drive housing. 
5. Remove the intermediate  cluster assembly. 
6. Remove the differential assembly. 
NOTE:  During dismantling  it is  essential  that 
all 
components  are marked  in...

LT 95 FOUR SPEED GEARBOX 
NOTE: If replacements  are required,  replace the 
following  items 
16 and 17 as sets. 
16. Bevel  pinions  and side  gears  (set of six). 
17.  Cross
-shafts  (set of two). 
18. Check the  gear teeth  for damage. 
19. Check all parts for  satisfactory  general condition 
including  the sidc gear bushcs. 
NOTE:  The differential  case halves  are a matched 
pair,  and halves  must not be changed  individually.  Assemble 
differential  to gearbox 
27.  Refit  the  differential...

LT 95 FOUR SPEED GEARBOX 137( 
13. Fit the remaining sealing ring and retaining  plate. 
14. Tighten the selector finger  pinch bolt. 
15. Select  ‘High’  transfer range,  that  is, the  larger 
intermediate gear engaged. 
16. Slacken  the selector  finger bolt. 
17. Rotate the cross-shaft until the gear  lever is 
inclined 45 degrees to the vertical  position. 
 
W17 ACO 
ST 1 21 9M 1- 
18. Tighten the selector finger  pinch bolt. 
19. 
Fit the  top  cover  using a new  joint  washer  and 
evenly...

37 
27. Fit the blanking plug to the  cross  drilling. 
28.-Fit the transfer  box top cover  using a new joint 
washer  and  evenly tighten  the bolts  to the  correct 
torque. 
29. Fit the  speedometer  drive housing. 
LT 95 FOUR SPEED GEARBOX 
RER E ND OVER€ 
SHAFT  AND HOUSING 
IUL FRONT OUTPUT 
Remove  output shaft assembly 
1. Remove  the differential  lock actuator assembly. 
2. Remove  the six retaining bolts, spring  washers and 
3. Withdraw  the output  shaft and housing  complete. 
4. Lift out...

.. 
LT 95 FOUR SPEED GEARBOX 
b- 
37 
REMOVE AND OVERHAUL BELL HOUSING  AND REMOVE  AND OVERHAUL  GEAR CHANGE 
CLUTCH  RELEASE  SELECTORS 
I. Withdraw the locating staple from the clutch 
2. Lift out the release  sleeve and bearing  assembly. 
3. Remove  the bell  housing  fixings and make  a note 
4. Withdraw the bell  housing  complete  with clutch 
5. If required,  remove 
the push  rod clip  and  the 
release 
slecve and 
release  lever. 
of  the  position 
of each  bolt and nut. 
release  lever....

1371 LT 95 FOUR SPEED GEARBOX 
Assemble gear change  selectors 
12. Withdraw  the retaining  pins from  the selector  jaws. 
13. Engage the cross-over  lever  and locate  fully in the 
groove 
in the  reverse  idler with the peg  in the  top 
of  the  cross
-over  lever  fully in the selector  finger. 
14. Start the pivot  bolt in the lever  threads.  Should it 
not start properly  move the lever  away  from the 
selector  finger but not out 
of engagement  with the 
idler. 
15. Locate  the first/second...