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  oil catcher and  back plate assembly. 
11. Drive  out the rear output  shaft, using a hide  mallet 
12. Slide  off the  spacer  and speedometer  worm. 
on 
the  threaded  end. 
3. Remove  the  eight  bolts and  withdraw the 
4. Remove the speedometer  spindle housing. 
6. Take off the 0 ring seal. 
7. Remove  the thrust  washer. 
8. Withdraw  the oil seal. 
speedometer 
drive housing. 
5 1 ift niit the driven opar and cnindlr b--. -..-  r-*---. d. Y... VI. L..V .A..... 
. .. ::,-. . . . 9. Remove  the  locking nut, using a flange  tool, .. . -, . .., washer  and felt seal,  output  coupling  flange to 
output shaft. 
.. :. .:. 
10. Withdraw  the coupling  flange complete. 
ST1025M 
13. Withdraw the  oil shield. 
14. Prise-out the  oil seal. 
15. Remove the  circlip. 
16. Tap out the ball bearing  race. 
39  
						

							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. 
Measure  the clearance  between the drive  housing 
and  gearbox 
joint faces.  This  must be 0,lO to 
0,15 mm (0.004 to 0.006 in) more  than the 
recorded  thickness  of the 
new joint  washer.  With 
the gasket  fitted and  the  bolts tightened  to  3 
kgf.m 
(22 Ibf.ft) a final rollingresistancc check should  be 
made  using 
a spring  balance  and string  wrapped 
round  the differential  case. The resistance  should 
be  14
-16 Ibs (6-7  kg).  The  differential  lock must  be 
disengaged  to allow  free rotation  of the 
unit whilst 
making  this 
chcck. 
To adjust  the joint  face clearance,  adjust the 
thickness  of shimming  fitted  behind the rear 
bearing  outer  face as 
follows: instructions 21 and 
22. 
Drive out the bearing  outer race. 
Withdraw  the shim  washer  and  selcct a 
replacement  of the  required  thickness.  Shim 
thickness  range is 
1,65 to 2,80 mm (0.065  to 
0.110 in) in 0,05 mm (0.002 in) stages.  Assemble 
the 
housing 
23. Fit the  rear  output  shaft ball bearing  and circlip. 
24.  Press 
in the output  coupling  flange oil seal,  open 
face  first, 
until the  seal  plain  face just  clears  the 
chamfer 
on the  seal  housing bore. 
25. Fit the oil shicld, which  must be a close fit on the 
speedomcter  housing. 
26. Fit the speedometer  worm Iollowed by the spacer. 
27. 
Fit the  rear  output  shaft. 
28. Fit the coupling  flange. 
29. 
Fit the  felt  seal,  plain  washer  and locking  nut to 
secure the output  flange and tighten  to  the correct 
torque. 
30.  Assemble  the following  parts 
to the speedometer 
spindle  housing: 
31. 
Fit the oil seal. 
32.  Fit 
the thrust washer. 
33. Fit a new 0 seal. 
35. 
Fit the speedometer  spindle  housing  assembly to 
#%i w,. .I 34. Fit the speedometer driven gear and spindle. . .I 
the drivc housing. 
Assemble  speedometer  drive housing  to gcarbox 
36.  Place  a new  joint  washer in position. 
37. 
Offer the  drive housing  to the  gearbox and engage 
the  rear output  shaft splines  in the  differential  unit. 
38. Position the flat on the  drivc  housing adjacent to 
the flat on the  intermediate  shaft. 
39. Secure the  assembly  with eight  bolts  and  evenly 
tighten 
to the correct  torque. 
40. 
Fit back  plate assembly. 
42.  Tighten  special  bolts  to 
55 to 60 Ibf.ft (75 to 80) 
$1. oil catcher and with dyiosii, 
noting that plain washers  are fitted. 
40  
						

							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 punched-out  before  the race  can be 
removed. 
Assembling 
Fit  the  transfer  gear to the  mainshaft. 
Fit the shim  washer  and snap-ring. 
Check  the  end
-float between the shim washer  and 
snap
-ring.  End-float  to be 0,050 mm (0.002  in) 
maximum.  Shim washer  range 
1,s to 2,O mm 
(0.071 to 0.079 in) in 0,05 mm (0.002 in) stages. 
Fit the  roller bearing  and rear  bearing housing. 
REMOVE  AND OVERHAUL  INTERMEDIATE 
GEARS  ASSEMBLY 
Special  tool: 
R01003 - slave intermediate  shaft 
1. Remove the speedometer  drive housing. 
2. Remove  the gearbox  bottom cover. 
3. Screw a suitable  extractor  into  the 8 mm threadcd 
hole provided in the intermediate  gear shaft. 
4. Hold  the  intermediate  gear cluster in position  and 
withdraw  the shaft. 
5. Insert the slave  shaft R01003 to retain together the 
gears  assembly. 
6. Withdraw  the intermediate gears  assembly. 
7.  Slide  the thrust  washers,  bearings  and gears  from 
8. The input  gear and outer  member is a riveted 
the 
slave  shaft. 
assembly  and no dismantling  is permitted. 
9. Remove  the ‘0’ ring seal  from  the intermediate 
gear shaft. 
10. Wash  and degreasc  all parts  and inspcct for  wear 
and  renew 
if necessary.  When new, the thrust 
bearing  washers have  a 
lead/tin coating, if this  only 
has  worn  away there  is no  need 
to renew  them. 
Assemble  intermediate  gears 
11. Place the slave  shaft on the bench, extractor  thread 
end  uppermost. 
12. 
Fit a pear-shaped  thrust  washer,  inner  ring and a 
thrust  bearing  washer 
to the shaft  (ring grooved 
face  downwards). 
13. Fit a needle-roller  bearing  and the ‘high’  gear 
(plain  face first)  to 
the shaft. 41  
						

							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 the  remaining thrust  needle  bearing,  inner  ring 
and  thrust washer (ring grooved face upwards). 
42 
ST121 
20. When  the  foregoing  bearing clearance  check  has 
been  completcd. 
slidc the gcars and slave shaft 
assembly into the transfer gearbox  and engagc thc 
selector forks. 
21. Withdraw the slave shaft  and lubricate the  bearings 
through  the shaft  aperture. 
22. Fit the intermediate  shaft and ‘0’ ring seal with the 
flat  on the  shaft  toward 
the differential unit. 
23. Measure  the  clearance  between  the  rear  thrust 
washer  and  the  gear casing.  This  must be 
0,15 to 
0,23 mm (0.006  to 0.009 in). 
24. Adjustment  is carried  out by substituting  one or 
both  of 
thc thrust  washcrs.  The washers  are 
available 
in 33.5 mm (0.139  in), 3,63 nini 
(0.143 in) and 3,74 mm (0.147 in) thicknesses. 
25. Refit the gearbox  bottom cover. 
26.  Refit  the  speedometer  drive 
housing. 
1 ST1213M  
						

							. .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 their  original  position  and 
relative  to other  components, 
so that if original 
components  are refitted,  their initial  setting 
is 
maintained. 
7. Press off the roller  bearings using tool 18G47BB. 
8. Withdraw  the high-speed  gear, which  is secured  by 
Loct i tc. 
I I ST1215M 
9. Remove the  fixings, low-speed gear to casing. 
10. Withdraw  the gear. 
11. Remove  the casing  securing bolts. 
12. Lift  off the rear case assembly  (and oil retaining 
ring 
- later gearboxes). 
13. Withdraw  the side  gear (and thrust washer - later 
boxes). 
14. Slidc out the  cross-shafts  and rcmovc the bevel 
pinions  and 
thrust washers from the front  case 
assembly. 
15. Withdraw  the side  gear (and thrust washer - latcr 
boxes) to dismantlc the front  case assembly. 
- 
ST1216M 
NOTE: From gearbox  numbers 1300 3481A and 1700 
0007A the following  modifications  have been made  to 
the  differential. 
A. Introduction  of side  gear  bushes. 
B. Improved  thrust washers. 
C. Addition  of thrust  washer  on side  gears. 
D. Modified  cross pins. 
E. Addition  of oil  retaining  ring. 
The  new  differential  part number 
FRC 7740 is only 
interchangeable  with superceded  unit part  number 
594 
340. 
43 
ST1799M  
						

							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  unit. 
28. Refit the speedometer drive  housing. 
29. Refit thc frofit output shaft and housing. 
30. Rcfit  the  diffcrential  lock actuator  assembly 
NOTE:  If a replacement  differential unit is being 
fitted,  carry out the ‘Differential  hearing pre
-load 
check’,  described  in ‘Speedometer  drive housing 
- 
Overhaul’. 
Assemble  differential 
CAUTION:  It is essential  that during  the following 
assembly  all components  are well  lubricated  with new oil 
of  the  correct  grade. 
20. 
Fit a  sidc  gear into  the rear casing. 
21. -Fit a side gear into  the front  casing. 
22. Fit the bevel  pinions,  thrust washers  and cross- 
shafts into the  front casing. 
23. Fit thc rear casing to the front  casing.  Tighten  the 
bolts evenly 
in sequence  to thc correct torquc.  Use 
Loctite  275 
on threads. 
24.  Offer  the 
low gear to the differential  casing. 
25. Align  the fixing  holes and fit the bolts evcnly in 
sequence  to the correct  torque. Usc Loctite 
26. Fit the roller  bearings  and refit  the diffcrential unit. 
REMOVE  AND OVERHAUL  TRANSFER GEAR 
LEVER  AND CROSS
-SHAFT 
1. Remove the top cover. 
2. Slacken  the selector finger pinch bolt. 
3. Drive out the  retaining  pin, gear  lever to cross- 
4. Withdraw  the gear  lever. 
5. Withdraw  the cross-shaft  and spacer. 
6. Lift out the  selector finger. 
7. Remove  the retaining  plates. 
8. Withdraw  the scaling  rings. 
shaft. 
ST121 
Assemble 
gear lever  and cross-shaft 
9. Position  the selector  finger in the gearbox. 
10. Fit the  cross-shaft  and spacing  collar and engage-i 
the selector finger. 
side  of the  gearbox. 
11. Fit the  sealing  ring and  retaining  plate  at the R.H. 
12. Fit the gear  lever and retaining pin. $5 *- ,/ NOTE: If the differential  case or bearings  have been 
replaced,  carry out the ‘Differential  bearing 
pre- 
load check’. 
44  
						

							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 tighten  the retaining bolts. 
. .I... . .. .... . .. . . , . . . . . .. . 
REMOVE AND OVERHAUL  TRANSFER BOX 
SELECTORS AND SHAFT 
1. Remove the  speedometer  drive housing. 
2.  Remove 
the transfer gearbox  top cover. 
3. Select ‘Low’ range transfer  gear. 
4. Drive out the retaining  pin from the front  selector 
fork  sufficient  to free 
the fork. 
5. Ease  the differential unit to the rear. 
6. Push  the  forward  selector  fork  forward on the 
shaft. 
7. Pull to the  rear on the  rear  selector  fork to move 
the  selector  shaft out of engagement 
with the 
detent  balls in the casing rear face. 
8. Remove  the pinch  bolt on the rear  fork. 
9. Partially withdraw  the selector  shaft  and lift out the 
selector forks. 
1.. 10. Remove the retaining  pin  from the front  fork. .. .. . . .h.,. . 11. Withdraw the selector  shaft, closing  the shaft 
housing 
by hand to prevent  the detent  balls  from 
dropping 
into the casing. 
,. 
12.  Withdraw the  two detent  balls. 
13. Lift out the spacing rod  and spring. 
14. Remove the  blanking plug. 
15. Withdraw the detent  spring from the  cross drilling. 
Assemble shaft and selectors 
16. Position the detent spring in the inncr bore in the 
17. Locate  the detent  ball on the spring. 
18. Enter the selector  shaft, push the ball against  the 
spring and  push 
in the shaft. 
19. 
Fit the  detent  ball, spring and  spacing  rod  to the 
vertical  drilling. 
20. Position thc rear  selector  fork, plain face to rear, in 
the gearbox. 
21.  Position 
the front  selector  fork, extended boss to 
the  rear, 
in the  gearbox. 
22.  Align  the  retaining  pin holes  and engage  the 
selector shaft 
in the selector forks. 
23. Fit the  retaining pin, front  fork to shaft. 
24. Set transfer  gears in ‘Neutral’ position. 
25.  Adjust 
the rear  fork  position  until there  is 0,12 to 
0,25 mm (0.005 to 0.010 in) clearance between  the 
front  face 
of the rear fork  and  the rear  face of the 
input  gear inner  member. 
cross drilling. 
26. Tighten the 
rear fork  pinch  bolt. 
45  
						

							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 the lock-up dog  clutch. 
gasket. 
0 Overhaul 
assembly 
5. Hold  the  output  shaft in a vice or use a flange & 
restraining  tool and  remove the flange  retaining 
nut and washer. 
6. Withdraw  the  coupling  flange complete with 
mudshield. 
7. If required,  press off the  mudshield. 
8. Press  out the shaft  toward the rear. 
9. Withdraw  the oil seal. 
10. Remove the circlip. 
11. Withdraw  the  output shaft bearing. 
12. Wash  and degrease all parts,  examine  for wear  and 
renew as  necessary. 
ST 1223M 
Assemble  output shaft assembly to housing 
13. Fit the output  shaft bearing  and secure  with the 
14. Fit the oil seal, lip side  towards the bearing. 
15. Press in the output  shaft from the rear. 
16. Fit the coupling  flange  complete with mudshield 
and  flange  bolts. Secure  with the locking  nut 
to the 
correct  torque. 
ci 
rcl i p. 
, 
46  
						

							.. 
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. 
spring  clip and  withdraw  the clutch  release  lever. 
1. Remove  the bell  housing. 
2. Select  neutral,  remove the reverse  light switch  and 
remove 
the gearbox  top cover  and joint  washcr. 
3. Lift out the dctent  springs. 
4. Withdraw the detcnt  balls, using a small magnet or 
5. Slacken  the pinch  bolt securing  the reverse  selector 
6. Drive out the four retaining  pins until  the shafts  are 
an 
air  blast. 
finger. 
free 
in the  selectors. 
ST1225M 
Assemble  clutch release and bell housing 7. Tap  out the selector  shafts. 
6. If removed, fit the release  lever spring  clip. 
7. Apply a thin film of Unipart  Universal or other 
suitable  jointing  compound  around the three 
selector  shaft holes 
in the bell  housing  rear face. 
8. Fit the bell  housing,  locating on the  dowels. 
9. Apply a thin film of molybdcnum disulphide grease 
onto  the 
front cover  extension  sleeve. 
10. Fit thc rclcase sleeve and bearing  assembly. 
11. Fit the locating  staple to the clutch reiease sleeve 
and  lever. 
8. Withdraw  the selector  jaws and forks. 
9. Withdraw  the two  interlock  plungers from the 
cross
-drilling. 
10. Rcmove the lock-wired  pivot bolt. 
11. Lift out the reverse  cross-over lever. 
Overhaul 
Examine  all parts  and renew if worn.  Renew thc detent 
springs.  Ensure that 
the retaining  pins are an 
interference 
fit, if not,  renew. 
.. 
ST 1 
47  
						

							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 gear selector  fork in the 
groove 
in the  outer  member,  with the boss  on the 
fork  to the 
rcar. Position  the boss  to the R.H. side 
of the  box. 
16. Locate  the third/fourth gear selector  fork in the 
groove 
in the  outer  member.  Position the fork  with 
the  retaining  pin entry  hole at the  top 
R.H. side. 
17. Fit the third/fourth gear  selector  shaft and 
interlock  pin assembly  and secure  to the  selector 
18. Fit the two  interlock  pins to engage  in the  grooves 
each  side 
of the third/fourth gear selector  shaft. 
19. Position  the reverse  stop hinge  plate and selector 
jaw in the gearbox,  adjacent to the third/fourth 
gear selector  jaw. 
20. Fit the  reverse  gear selector  shaft and engage  the 
selector  jaw and 
hinge spring. 
21. Push  the shaft  home  and engage  the reverse  cross- 
over lever  selector  finger. Do not secure  the pinch 
bolt  at this  stage. 
22. Secure the revcrse gear  selector  jaw to the shaft 
with  a retaining  pin. 
. fork with a retaining  pin. 
24 23 2a01 15 25 A+- +* 
ST 1227M 
23. Posi!i~n thp first,/secogd up?ir cplprtnr iaw in the b- w--Va J 
gearbox. 
24. Fit the first/second gear selector  shaft; engage  the 
selector  jaw and  selector  fork 
as the shaft is pushed 
home. 
25. Fit the  retaining  pins, fitting  the rear  pin first. 
26. Move  the reverse  shaft forward  until the selector 
jaw  abuts  the casing. 
27. Holding  the reverse  shaft  as  described in the 
previous  item, move  the reverse  selector  finger 
forward 
on the  shaft  until it abuts  the casing,  then 
move it rearward  until it is just  clear  of the  casing. 
28. Place a 0,25 mm (0.010 in)  feeler  gauge  between 
the  upper  edges of the  reverse  and 
third/fourth 
selector jaws. 
NOTE: The edges  of the  selector  jaws taper  slightly, 
therefore, 
it is important  that the feeler  gauge  is 
positioned  between the upper  edges. 
29. Hold the reverse  and third/fourth selector  jaws 
together  to retain  the feeler  gauge, 
then rotate  the 
reverse  selector  finger until it abuts  the 
third/fourth 
selector  shaft and tighten  the pinch  bolt. 
30. Wire lock the cross-over  lever  pivot  bolt. 
31. When  fitting the hinge  spring  to the  reverse  stop 
hinge,  first engage 
the large  hook  around  the 
selector  shaft, as illustrated,  before fitting the small 
hook 
to the  reverse  stop hinge  pin. 
48