Land Rover Defender 90 110 Workshop 1984 Rover Manual

LT95 FOUR SPEED  GEARBOX (371 
6. Lift out the reverse  idler gear assembly. 
7. Remove  the circlip  and plain  washer. 
8 Lift out the needle rollcr bearings  and further  plain 
washer. 
9. Withdraw the remaining  circlip. 
9 
32. Fit the  detent  balls and springs. 
33.  Selcct  neutral  and using  a new  joint  washer, 
fit thc 
gearbox  top cover  and secure  with the eight  bolts, 
T 
and evenly  tighten to the correct  torque. STl23 1 M 
34. Fit the reverse  light switch 
35.  Fit the  bell...

LT 95 FOUR SPEED GEARBOX 
REMOVE AND OVERHAUL FRONT COVER  AND 
OIL PUMP 
Service tools: 
R01005 - Centralising tool 
18G134 - guide and 
18G134DG - assembly tool for fitting  oil  seal  and oil 
feed ring. 
1. Lift out the retainer  staple from the clutch  release 
bearing  assembly  and 
the release lever. See clutch 
release  overhaul. 
2. Withdraw  the release  bearing  assembly. 
3. Remove  the slave  cylinder pushrod. 
4. Remove  the spring  clip. 
5. Withdraw  the clutch  release  lever. 
6....

LT 95 FOUR SPEED GEARBOX (37( 
Fit cover  assembly to gearbox 
19. Position  the layshaft  bearing shim washer. 
20.  Position 
the front  cover  assembly  and loosely  fit 
the  fixings. 
21. Fit  the  oil pump  drive gear to engage  the drive 
square 
in the  layshaft. 
22. 
Fit the  oil pump  cover and joint  washer  and fit the 
fixing  screws  and washers  and carefully  tighten to 
the  correct  torque. 
23. Fit the gauge R01005 to align  the primary  pinion 
with the bell housing. 
24. Visually...

LT 95 FOUR SPEED GEARBOX 
REMOVE AND OVERHAUL  PRIMARY PINION 
1. Remove the bell  housing. 
2. Remove  the front  cover  and oil pump  assembly. 
3. Remove  the bearing  plate assembly. 
4. Remove  the circlip. 
5. Lift  off the  shim  washer. 
6. Press  out the primary  pinion. 
ST 1 240M 
7. Withdraw the bearing retaining  plates and serrated 
8. Press  out the primary  pinion bearing. 
bolts.  ~  ~~~  ~  ~~  ~ 
Assemble 
primary pinion 
9. Check that the orifice drilkd in the oil tube  is clear. 
10....

LT 95 FOUR SPEED GEARBOX 1371 
- -. ..._ __ ,.~ ., .1-. REMOVE AND OVERHAUL THE MAINSHAFT 
.....,. . ., ASSEMBLY .. . . ..L ...,. ., .. ... ..-. . 
Special  tool: 
1861388 -extractor  for mainshaft  spacer and gear 
1. Remove  the bell  housing. 
2. Rcmove  the front  bearing  plate. 
3. Remove  the main  gearchangc sclectors. 
4. Removc  the mainshaft  rear bearing  housing  and 
5. Remove  the bottom  cover from the transfer 
roller 
bearing. 
gearbox. 
NOTE: At  this  stage  in the  dismantling,  on...

LT 95 FOUR SPEED GEARBOX 
Overhaul  mainshaft assembly 
Dismantle 
15. Withdraw thc first-speed  gear, thrust  washers  and 
roller  bearings  from the rear 
of the shaft. 
16. Remove  the snap-ring  and shim  washer  from thc 
front of the shaft. 
17. Lift off the third/fourth gears  synchromesh 
assembly. 
18. Withdraw  the third  and second-speed  gears and the 
associated  thrust washers  and 
needle-rollcr 
bearings. 
19. Dismantle  the third/fourth gears synchromesh 
assembly,  first pushing  down...

.,.. ,.  .. ., -... . r ,: 5 -.: : . . .: . ,. .. 
LT95 FOUR SPEED GEARBOX 137 
34. Fit a scalloped  thrust washer,  a thrust  needle 
bearing  and 
a further scalloped  thrust washer. 
35. 
Fit a radial  needle  bearing  and the third-specd 
gear. 
36. 
Fit a  scalloped  thrust washer,  a thrust needle 
bearing  and a further  scalloped  thrust washer. 
37. Position  a synchromesh  cone onto the third-speed 
gear. 
38. 
Fit the synchromesh  unit, coned  face to rear. 
Set  end-float  of gears 
39....

137 I LT 95 FOUR SPEED GEARBOX 
55. Engage the shaft into the main  bearing. 
56. Engage  the first/second gear synchromesh  outer 
member  and the reverse  idler gear. 
57.  Push  the mainshaft 
home enough to allow  the 
mainshaft  spacer to 
be locatcd on the  rear  end, 
with 
the spacer  larger diameter  forward of the 
transfer  gear lever  cross
-shaft. 
60 
58. Re-position  the first-speed  gear, thrust  washers 
and  thrust  needle  bearing  correctly on the 
mainshaft. 
59. Push the mainshaft...

LT 95 FOUR SPEED GEARBOX 
,:.:.:.. i.: *:, 1 ... ... ..,; 7. Extract the layshaft  rear bearing  outer member 
from  the gearbox  casing, extiaetor  186284 and 
adaptor 
18G284AR. 
12.  Press the rear  bearing  outer member  into the 
13. Enter the front  bearing  outer member  into the 
.. I. :..:! gearbox  casing. 
front  bcaring  plate. 
DO not fit fully in at this  stage. 
37 
. 
8. Withdraw  the bearing  inner members  from the 
layshaft.  Extractor  18647 press and 
18G47BA 
col tars. 
n 
ST 1258M...

37 
21. Measure the rolling  resistance  of the  layshaft,  using 
a  spring  balance  and a cord  coiled  around  the 
layshaft  larger diameter.  The rolling 
rcsistance 
must be 7 to 3,38 kg (6 to 7.5 Ibs). 
REMOVE AND  OVERHAUL  DIFFERENTIAL  LOCK 
ACTUATORASSEMBLY 
1.  Remove  the four  bolts  and  withdraw  the assembly 
from front output shaft  housing. 
2. Remove  the detent  spring and ball. 
LT 95 FOUR SPEED GEARBOX 
22. To adjust  the pre-load, fit a replacemcnt shim or 
suitable  thickness to...