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  must be flameproof  and kept clear of spillage. 
NO  ONE 
SHOULD BE PERMITTED  TO REPAIR  COMPONENTS  ASSOCIATED  WITH  PETROL! 
GASOLINE  WITHOUT FIRST 
HAVlNG HAD SPECIALIST  TRAINING. 
FUEL TANK  DRAINING 
WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST 
IT IS STANDING  OVER A PIT. 
Draining or extracting petroligasoline from vehicle fuel tank must be carried  out in a well ventilated area. 
The receptacle  used to contain  the pctrol/gasoline must be more than adequate  for the full amount or fuel to be 
extracted 
or drained.  The receptacle  should  be clearly  marked  with its contents,  and placed in a safe storagc area 
which  meets the requirements  of local  authority  regulations. 
WHEN 
PETROL/GASOLINE HAS  BEEN  EXTRACTED OR DRAINED  FROM  A FUEL  TANK  THE 
PRECAUTIONS  GOVERNING NAKED LIGHTS  AND IGNITION  SOURCES SHOULD BE MAINTAINED. 
FUEL TANK REMOVAL 
On vehicles  where  the  fuel line is secured  to  the fuel  tank  outlet  by a spring  steel clip,  it  is recommended  that such 
clips  are released  before the fuel  line  is disconnected  or the  fuel  tank  unit is removed.  This procedure  will avoid  the 
possibility 
of residual  petrol fumes in the fuel  tank being  ignited  when  the clips  are relcased. 
As an added  precaution  fuel tanks should  havc a PEIROL/GASOLINE VAPOUR  warning label attached  to them 
as soon as 
they are  rcmovcd from the vehicle. 
FUEL TANK REPAIR 
Under  no  circumstances should  a repair  to any  tank involving  heat  treatment  be  carried out without  first rendering 
the  tank  SAFE,  by 
usingone of the  following  methods: 
STEAMING:  With the filler  cap and  tank  unit  removed, empty 
the tank. Steam thc tank for at least  two hours 
with low  pressure  steam. Position  the  tank so that  condensation  can drain  away freely,  ensuring  that any 
sediment  and sludge 
not volatiscd  by the  steam,  is washed  out during the steaming  process. 
BOILING:  With the filler  cap and  tank  unit  removed, 
empty the tank. Immerse the tank  completely in boiling 
water  containing 
an effective  alkaline  degreasing  agent or a dctcrgent, with the  water  filling  and also 
surrounding the  tank 
for at least  two hours. 
After  steaming  or boiling 
a signed  and dated  label to this effect should  be attached to the tank. 
SPECIFICATION 
Purchasers  are advised  that the specification  details set out in this Manual apply to a range of vehicles  and not to any 
one. 
For the  specification of a particular  vehicle, purchasers should  consult their Distributor  or Dealer. 
The  Manufacturers  reserve the right 
to vary  their  specifications  with or without  notice,  and at such times  and in such 
manner  as 
they think fit. Major  as well as minor  changes  may be involved in accordance  with the Manufacturers 
policy  of constant product  improvement. 
Whilst  every  effort  is 
made to ensure  the  accuracy of  the particulars  contained in this Manual,  neither  the 
Manufacturer  nor the  Distributor 
or Dealer.  by whom  this  Manual is supplied,  shall in any circumstances bc held 
liable  for any  inaccuracy  or the  consequences  thereof. 
COPY RIGHT 
0 Land Rover  Limited 1984 
All rights reserved.  No part  of this  publication  may  be  produced, stored in a retrieval  system or transmitted in any 
form,  electronic,  mechanical,  photocopying,  recording 
or other means  without  prior writtcn permission  of Land 
Rover Limited,  Service Department,  Solihull, England. 
... Ill  
						

							. 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 tools  or standard equipment. 
The  user  is therefore 
assurcd that  the tool is ncccssary  and  that it will  perform accuratcly, 
efficiently  and safely. 
Special  tools 
bullctins will be issued periodically  giving details of new tools as thcy are introduced. 
All orders  and  enquiries from the  United  Kingdom should be sent dircct to V. L. Churchill. 
Overseas orders  should  be  placed  with the local V. L. Churchill  distributor,  whcrc one exists. 
Countries  whcrc thcrc 
is no distributor  may ordcr dircct from V. L. Churchill  Limited, PO Box 3, 
Daventry, Northants,  England NNll 4NF. 
Thc tools rccommended in this  Workshop  Manual are listed in a  multi-language,  illustrated cataloguc obtainable from 
Messrs. 
V. L.  Churchill  at thc above addrcss under publication number 221?!2!84 or from  Land  Rover Ltd.,  under part 
number 
LSM0052TC from the following  address,  Land  Rover  Publication Scrvicc, P.O. Box 534, Erdington, Birmingham, 
B24 OQ5.  
						

							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 switch 
wires  from the 
R.H. side of the gearbox. 
30. Disconnect the wire  from the reverse  light switch 
situated  at the  top  rear  of the  selector  housing  and 
rnove  the harness  away from the transmission. 
31.  Support  the engine  under the sump  with a jack, 
placing  timber between  the jack  pad and sump. 
32.  Remove  the eleven  hell housing  nuts. 
33.  Withdraw  the transmission  whilst ensuring  all 
connections  to the  engine  and chassis  are released. 
Separating the transfer box  from gearbox 
41. Withdraw  the transfer  box. For LT230 transfer 
gear  box dismantling  refer to page  19. Dismantling 
information 
on LT77 gearbox,  refer to page 3. 
Assembling transfer box to  main gearbox 
42. Hoist  the transfer  box into  position  and ensuring 
that  the loose  upper  dowel  is fitted,  assemble  to 
main  gearbox  extension  housing and secure 
with 
the four  bolts  and two nuts. 
43. 
Fit the  transfer  selector  housing to the main 
gearbox  remote gear change  housing 
with the four 
bolts.  (The right hand  rear bolt is longer). 
44. Fit the  breather  pipes. 
45. 
Fit the  diffcrential  lock cross shaft lever  pivot 
bracket  to the  extension  housing 
with thc two 
bolts. 
46.  Connect  the cranked 
lever to the  differential  lock 
lever 
with a  new  split  pin. (On early  production 
connect  the short 
link with  a new  ‘Nyloc’  nut). 
Fitting main gearbox  and transfer  box to engine 
47. Fit the cradle to the  transmission  hoist and the 
transmission  to the  cradle  as described 
in 
instruction  23. Smear  Hylomar on bell housing  face 
mating  with engine. 
48. Locatc  the gear lcver temporarily  and select  any 
gear 
in the  main  gearbox to facilitatc entry of the 
primary  shaft. 
49. Position  and raise  hoist  and fit the transmission  to 
the  engine  whilst keeping  wires and pipes  clear to 
prevent  trapping. 
50. Secure the transmission to the  engine  with the 
eleven  nuts, noting  that the 
top R.H.  nut holds  a 
clip  for the  speedometer  cable. 
51. Position the revcrse light wires  to the R.1-I. side  of 
the  main  gearbox  and secure  with a cleat 
to the 
breather  pipes. 
top 
rcar of  the  selcctor  housing. 
53. 
Conncct the  differential  lock indicator  wires (bullet 
connection). 
54. Raise thc transmission  to line-up  with  the engine 
and  ensure  that 
the transfer  lever clears  the tunnel 
aperture. 
55. Fit the  transfer  box L.H.  and R.H.  mounting 
brackets  but only  partially  tighten the securing  nuts 
and  bolts. 
56. Loosely fit the rubber  mounting  nuts and lower  the 
transmission 
onto the mountings.  Fully tighten  all 
the  securing  nuts and bolts. 
57. Remove  the supporting  jack from  under  the engine 
aurrrp. 
58. Remove  the two  bolts  securing  the cradle  to the 
transfer  box and remove  the cradle  and hoist. 
59. Refit thc two  bolts  using  Loctite 290 on the threads 
and  note  that 
the L.H.  bolt holds  a clip  for the 
speedometer  cable. 
60. Fit the  slave  cylinder  using Hylosil  on the  gasket 
and  tighten 
the two  bolts  evenly  to 22 to 28 Nm (16 
to 21 Ib ft). 
52. 
Connect  the reverse  light wire  to 
the switch  at the 1 
,...--  
						

							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 the filler  plug. 
Similarly  remove 
the transfer filler  level  plug  and 
inject  approximately 
2,6 litres  (4.5  pints) of 
recommended 
oil or until  it runs  out of the filler 
hole.  Apply  Hylosil 
to the  threads  and fit the plug 
and  wipe  away  any surplus 
oil. 
64. Line  up  the marks  and fit the front  and  rear 
propeller  shafts to the  transfer box. 
65. 
Fit the  exhaust  system,  and  evenly  tighten the 
flange nuts  and bolts. 
Fit the ‘U’ bolt and secure  to 
- the bracket. 
66.  Expand  the chassis  side  members, fit the  cross 
member  and  secure  with the eight 
nuts and  bolts 
(four each  side). 
67. Fit the heater  pipe clamp. 
68.  Clip  the  breather pipes,  specdometer  cable and 
69. 
Fit thc fan  cowl. 
70. 
Fit the bonnet. 
71. 
Fit main  gear lever  gaiter and  lever, to previously 
marked  spline setting.  Secure with 
the 10 mm 
‘Nyloc’  nut (with  plain  washer)  to  the correct 
torque.  starter motor harness 
to rear 
of engine. 
72. 
Fit the  cover  to both  gear levers. 
73. 
Fit the gear  lever knobs. 
74. Connect  the battery. 
OVERHAUL  LT77 FIVE SPEED GEARBOX 
(4  cylinder  petrol and diesel) 
Service  Tools: 
18G705 - Bearing  remover 
18G705-1A - Adaptor  for mainshaft 
18G705-5 - Adaptor  for layshaft 
18G1400 - Remover for synchromesh  hub and gear 
cluster 
18G1400-1 -Adaptor  mainshaft  5th gear 
MS47 
- Hand  press 
18G47BA -Adaptor,  layshaft bearing remover 
18647BAX -Conversion  kit 
186284 
- Impulse  extractor 
18G284AAH - Adaptor  for input  shaft pilot bearing 
track  1861422 
- Mainshaft  rear oil seal replacer 
!8G!431 - Mainshaft 5th gear and oi! sea! cellar 
replacer 
Dismantle 
1.  Place  gearbox on  a bench with the transfer 
gearbox  removed, ensuring  the oil is first  drained. 
2. Remove the clutch  release bearing carrier  clip. 
3.  Remove 
the clutch  release  bearing  and carrier. 
.. 
4. Pull  the clutch  release  lever from the clutch 
5. Rcmove  the bolts  and washers securing  the clutch 
release 
lever pivot. 
release  lever pivot. 
6. Remove the bolts  and washers  securing  the bell 
housing  and remove  the bell  housing. 
7. Remove the three bolts  and washers retaining the 
gear  selector  housing to the fifth gear extension 
case.  Lift the housing  from the case  and discard 
the gasket. 
P8 
ST541 M I I 
8. Using  a  suitable  pin punch,  remove  the  roll pin 
retaining  the selector  yoke. 
9. Push the selector shaft  forward to engage a gcar, 
and  manoeuvre  the selector  yoke  from the shaft. 
Return  the selector shaft 
to neutral. 
10. Remove  the circlip which  retains  the mainshaft oil 
seal collar  located at the  rear  of the  gearbox. 
3  
						

							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  bolts  and spring  washers  securing 
the 
fifth gear  selector  fork and bracket. 
17. Withdraw  the fifth gcar selector  spool. 
18.  Withdraw  the fifth  gear  selector  fork and bracket. 
19. On early  models,  remove circlip retaining fifth 
gear (driving)  from the layshaft.  On later  models, 
engage  reverse gear by turning  selector  raii anti
- 
clockwise  and pulling  rearwards.  Move the fifth 
speed synchro  hub into mesh with the fifth  gear. 
De
-stake  the retaining  nut securing  the fifth  gear 
iayshaft  and remove  nut. Select  neutral  by 
pushing  selector 
r;3il inwards and turning 
clockwise;  and return  fifth speed  synchro  hub to 
its  out  of mesh  position. 
4 
21 
ST 908M 
W 
20. Release  the circlip  retaining  the fifth  gear 
synchromesh  assembly to the  mainshaft. 
21.  Using 
tools 18G1400-1 and 18G1400 withdraw  the 
selective  washer, fifth gear  synchromesh  hub and 
cone, 
fifth gear  (driven)  and spacer  from the 
mainshaft. 
22.  Remove  the split  roller  bearing  assembly  from the 
main  sh 
a ft. 
23. Using  tools 186705  and 18G705-1A remove the 
layshaft  spacer (if fitted)  and layshaft  fifth gcar. 
ST 
24. Remove  the selector  shaft circlip. 
25. Fit suitable  guide studs (measuring 8 x 60 mm) to 
26. Locate the gearbox to a suitable  stand. 
27.  Remove  the six bolts  and spring  washers  from the 
front  cover.  withdraw  the cover  and discard  the 
gasket. 
28.  Remove  the input  shaft and layshaft  selective 
washers  from the gearcase. 
29. Remove  the two  bolts  and washers  securing  the 
locating  boss for the  selector  shaft front  spool, 
withdraw  the locating  boss. 
30. Withdraw  the selector  plug, spring  and ball  from 
the  centre  plate. 
the 
main  gearbox  case. 
c-) .  
						

							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 and fourth  gear . synchromesh  cone. 
37 
36. Rotate the fifth gear selector  shaft clockwise 
(viewed  from above)  to align  the 
fifth gear 
selector  pin with  the 
slot in the centre  plate. 
37.  Remove  the mainshaft  and selector  fork 
assemblies  from the centre  plate. 
38.  Detach 
the selector  fork assembly  from the 
mainshaft  gear cluster. 
39. Remove  the slave  bolts from thc centre  plate and 
lift the centre  plate clear of the  stand. 
Front cover 
40. Remove  and discard  the oil seal from  the front 
cover. 
Do not fit a new oil  seal  at this stage. 
Layshaft 
41. Using prcss 18G705 and  tool 186705-5 remove 
the  layshaft  bearings. 
37 - 
.. 
ST545M 
ST 
5  
						

							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 
a suitable press. 
45. Using  press  MS47 and extension,  with a  support 
underneath  the third 
speed gear,  press  the 
mainshaft  through the pilot  bcaring  spacer, third 
and  fourth  synchromesh  hub, third  gear 
synchromesh  cone,  third gear  and  third  gcar 
needle  roller bearing. 
55. Using  tools  MS47  and 18G47BA, reniovc the 
56. With  the aid of tools 18G284AAH and  186284, 
input shaft 
bearing. 
cxtract the pilot  bearing  track. 
First and second  gear synchromesh  assemblies 
46. Mark  the hub  and  sleeve  to aid  reassembly  and 
remove the  slipper rings from the front  and rear 
of 
the first  and second  gear synchromesh assemblies. 
47. Withdraw the  slippers and hub from thc sleeve. 
Third  and fourth  gear synchromesh  assemblies 
48. Mark  the hub  and slecve to aid  reassembly  and 
remove the  slipper rings from 
the front and  rear of 
the assembly. 
49.  Withdraw 
the slippers  and hub from the sleeve. 
Extension  case 
SO. Remove the three  oil pump  housing  bolts,  spring 
51. Do not withdraw the oil pick-up pipe. 
52.  Remove  the plug,  washer  and filter. 
53. Invert  casing  and extract  the oil seal. 
54.  Press  out the ferrobestos  bush from the  casing. 
washers and 
oil pump gears. 
6 
4 ST 873M 
Reverse  idler gear 
57. Remove  the circlip  from the reverse idler  gear. 
58. Having noted their positions, remove both ncedle 
roller  bearings  and remaining  circlip from  the 
gear. 
Fifth  gear synchromesh  assembly 
59. Lever the backing  plate off the fifth  gear 
60. Remove  the slipper  rings from  the  front and  rear 
61.  Release  the  slippers  and slide  the hub  from  the 
synchromesh assembly. 
of  the  assembly. 
sleeve.  
						

							~~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, pin and  fifth  speed 
selector  pin. If 
it is required  to replace  the first 
and  second  selector  fork on its own,  press  out the 
fifth  speed  gear selector  pin and  remove 
the first 
and  sccond  selector  fork from  the selector  rail. 
* . .. 
Gear selector  housing - Latest models 
66. Remove the roll pin and  release  the bias  spring. 
67.  Remove 
the two  adjusting  screws and locknuts. 
68.  Remove  the gear  lcvcr 
cxtension, secured  by a 
nut  (with 
phi n wash  er) . 
69. Remove  the bolt  and special  lock washer  to 
release 
the gear  lever  shaft from  the trunnion 
housing. 
70.  Remove  the 
four bolts and spring  washers 
retaining  the gear  lever  housing  to the  selector 
housing.  Lift 
off the housing  and discard  the 
gasket. 
(a) Rcmove  the gear  lever  gaiter  and three  bolts 
holding 
the gear  lever  retaining  plate and 
anti
-vibration  pad. 
(b)  Remove  gear lever  from the gear  lcvcr 
housing. 
(c)  Removc  the four  bolts  and spring  washers 
retaining 
the gcar levcr housing  to the 
selector  housing.  Lift off the  housing  and 
discard  the gasket. 
(d)  Remove  the bolts  and washers  retaining  the 
fifth  gcar  plunger  assembly.  Care must be 
taken  not to lose  the shims  located 
on the 
plunger  assembly  casting. 
(e)  Withdraw  the asscmbly  from the selector 
housing  and label  components  for 
identification 
on reassembly. 
71.  Rcmove 
thc bolts  and washcrs  retaining  the 
reverse  gear plunger  assembly.  Care must be 
taken  not to lose 
the shims  located on the 
assembly  casting. Detach from the selcctor 
housing  and label  components  for identification. 
72.  Remove 
the locating  bolt from the housing  for 
nylon  bush.  Pull the selector  shaft rearwards  and 
remove 
the trunnion  housing. 
73.  Release  the circlip  and detach  the nylon  insert 
from  the trunnion  housing. 
74.  Invert  the gear  selector  housing and 
removc the 
fifth  gear 
spool retainer  bolts and spring  washers. 
Lift  off the 
fifth gear  spool  retainer. 
75.  Remove  the large  blanking  plug at the  rear  of 
the 
housing . 
76. Remove  the reverse  switch blanking  plug. 
77.  Place  the gear  selector  housing into protected  vice 
jaws,  using 
a suitable  pin punch,  drift out the 
selector  yoke 
roll pin. Push the selector  shaft 
forwards  and remove  the selector  yoke. Remove 
housing  from vice. 
.# ./ 
ST548M 77 
78. Remove  the selector yoke roller  circlip  and 
79.  Withdraw  the gear  selector  housing shaft out 
80. Remove  and discard  the gear  selector  shaft ‘0’ 
7 
withdraw  the pin  and  rollers. 
through  the large  blanking  plug orifice. 
ring.  
						

							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  assemblies. If 
there  is evidence  of chipping 
or excessive  wear, 
install  new parts on reassembly. Check  all slippers 
and  slipper  rings for wear 
or breakage.  Replace 
with new 
parts if necessary. 
87. Inspect  all circlip  grooves  for burred  edges. If 
rough or burred,  remove condition  carefully using 
a fine file. 
58. Ensure all oil outlets  are clear  of sludge or 
contamination  especially the mainshaft  oil  ways. 
Clean  with compressed  air observing  the 
necessary safety  requirements. 
89. During the rebuild operation, it is recommended 
that new roller and needle bearings  are fitted. 
ASSEMBLY 
ST549M 
Reverse  gear plunger  assembly 
83. Remove  the plug,  long  spring  and  detent ball 
from the reverse  gear plunger  assembly. 
84. Detach  the circlip  which  retains the reverse  gear 
plunger,  pull 
out the plunger  followed  by the 
short  spring. 
Labcl all parts  and keep separate 
from  the 
fifth gear plunger  assembly. 
ST550M 
Cleaning  and inspection 
85. Clean  gearcase  thoroughly  using a  suitablc 
solvent.  Inspect  case  for cracks,  stripped  threads 
in the  various bolt holes,  and machined  mating 
surfaces  for  burrs,  nicks or any  condition  that 
would  render  the  gearcase 
unfit for  further 
service. If threads are stripped,  install Helicoil, or 
equivalent inserts. 
8 
Layshaft 
90. Using  tools MS47 and a suitable  tube, fit new 
bearing cones to the layshaft. 
Synchromesh  assemblies 
91. With the outer sleeve  held, a push-through load 
applied to the outer face of the synchromesh  hub 
should  register  8,2 to 
10 kgf m (18  to 22 Ibf ft) to 
overcome the  spring detent in either direction. 
92. Assemble  the  first and second  synchromesh 
asscmbly  by locating  the shorter 
splincd face 
towards  the second  gear. 
92 
ST551M