Land Rover Defender 90 110 Workshop 1984 Rover Manual

							LT85 FIVE SPEED GEARBOX 
,: ..: ,. z..:. -... .. 27. Tap  down 3rd/4th jaw roll pin until jaw is free on : ;$ .._ji  selector  rail. .:: .-,. 
28. Withdraw 3rd/4th selector  rail and  jaw. 
20. Remove  interlock  from 3rd/4th sclcctor rail. 
30.  Tap  down 
lst/2nd jaw roll pin until .jaw is free  on 
sclector  rail. 
31. Remove  clamp bolt from Isti2nd selector fork and 
withdraw 
lst/2nd selector  rail and jaw. 
32.  Remove  interlock  from lst/2nd sclcctor rail. 
33.  Lift  rcverse  cross
-over lcvcr rrom gearbox. 
34. Remove 1st/2nd and 3rd/4th selector forks. 
37 
35. Remove  interlock  plungers and also dctcnt balls if 
not removed in operation 19. 
STI 
36. Remove two bolts, 
spring  washers  and plain 
washers  securing  5th gear  fork and bracket 
assembly  to gearbox. 
Do not displace selector  fork 
slipper  pads when  removing  fork. 
Kevcrsc idlcr shaft, mainshaft  and layshaft 
37. Remove  circlip, selective  washer, oil seal  collar  and 
0 ring from mainshaft. 
ST1328M 37 
II ST1329M 
38. Remove 5th gear synchro  hub and baulk ring. 
39.  Remove  5th gear,  spacer, needle roller bcaring  and 
thrust  washer. 
ST1330M 39 
69  
						

							E[ LT85 FIVE SPEED GEARBOX 
40 
40. Remove  mainshaft  rear bearing  circlip. 
41. Release  stake nut collar  from recess in layshaft, 
remove  stake nut and  5th gear  from  layshaft. 
NOTE: To facilitate  this  operation lock gearbox  by 
engaging  both 
1st and 4th gears. 
ST1332M e 
41 
42. Fit manufactured  spaccr to layshaft to retain  rear 
bearing  and secure 
in position with stake  nut 
finger
-tight  only 
42 ST 
43. Disengage  1st and  4th gears. 0 7..::. 
44. Remove two socket hcad set screws  and two bolts 
with  spring  washers  and remove  reverse shaft and 
layshaft  bearing track retaining  plate. 
4.5. Remove reverse lcver pivot bolt and lift reverse 
lever  from gearbox. 
’* 
$3: 
a&&. i. . I.. ..;, 45 
ST1334M 
46. Fit extractor  adaptor Tool No. LST 284-1 to 
reverse  idler shaft. 
47. Fit slide  hammer Tool No. MS 284 to adaptor  and 
withdraw  reverse idler shaft  from gcarbox.  Reverse 
idler  gear and thrust  washer  will drop  into bottom 
of gearbox. 
48. Kcmove  seven bolts and spring  washers  and 
withdraw  front cover  and gasket  from front  bearing 
plate. 
70  
						

							LT85 FIVE SPEED GEARBOX I37 I 
49. Remove  layshaft front bearing  spacer. 
50.  Remove  input shaft bearing  circlip and selective 
51.  Remove  bolts and spacers  retaining  front bcaring 
washer. 
plate 
to gearbox. 
56 
57 
ST1336M 
50 
58. Extract  mainshaft from rear bearing. To facilitate 
operation  assistance  will be needed 
to support 
mainshaft  and layshaft. 
59.  Tap  layshaft  forwards  and remove  rear bearing 
race. 
60. Withdraw  mainshaft and layshaft  assemblies. 
61. Remove  rcvcrsc idler gear and thrust  washer from 
gearbox. 
52. 
Fit plates  and spacers of Tool No. LST 1431-1 to 
front  bcaring 
plate with 90 mm bolts. 
53.  Locate  two legged  puller 
Tool No. 18G 1400 as 
shown  and remove  front bcaring  plate 
from input 
shart and gearbox. 
NOTE: Centre  bolt and lcgs of puller  must be 
aligned squarely  with input  shaft. 
OVERHAUL 
52, 
53 
Main gearbox  case 
1. Remove  drain plug. 
2. Remove  retaining plug and oil filter. 
3. Remove filler/level plug. 
4.  Remove  interlock  cross drilling  plug. 
ST1337M 

						

							37 LT85 FIVE SPEED GEARBOX 
7. Position gearbox on suitable  wooden  blocks and 
remove  mainshaft  rear bearing  using 
Tool Nos. 
LST 550-3 and MS 550. 
7 
8. Remove  rear bearing  circlip and clcan. 
9. Using Tool Nos. LST 550-2 and MS 550 remove 
layshaft  rear bearing  outer track. 
NOTE: Use rounded  end of tool. 
10. CIea 
STl34 1 M 
earbox case asket faces, in erior and  12. 
Clean  mainshaft  and layshaft  bearing seatings. 
13. Clean rcverse  gear idler  shaft  seating,  drain plug, 
14. Using  an air  line  blow  out filter  plug tapping and 
15. Clean  top cover facc and  5th gear  fork bracket 
16. Hcat gearbox  case to facilitate  fitting of mainshaft 
17. Fit circlip to mainshaft  rear bearing. 
18. Position  rear bearing in gearbox  seating. 
19. Using Tool Nos. LST 550-3 and MS 550 tap rear 
and 
level/filler plug 
tappings. 
oil
-way,  detcnt  and interlock  seatings. 
dowels. 
rear  bearing  and layshaft  bearing track. 
bearing  into position. 
Y 
191 
ST 
20. 
21. 
exterior  and inspect for cracks  and obvious  signs of 
damage  etc. 
11. Clean magnetic  drain-plug, oil filter  retaining  plug, 
level/filler plug and oil filter. 
72 
ST1343M 
With  gearbox  still warm fit layshaft  rear bearing 
outcr  track using 
Tool Nos. LST 550-2 and MS 550. 
Refit  interlock  drilling plug. 
22. Refit lcvel/filler plug - do not tighten at this  stage. 
23.  Refit  oil filter  and retaining  plug using  new copper 
z;:.,, ,e- : .., . washer. .. ,. 
24. Refit  magnetic  drain plug and new copper  washer. 
20  
						

							. 
LT85 FIVE SPEED GEARBOX 37 
Front bearing plate 
1. Support front bearing  plate on suitable  wooden 
2. Using Tool Nos. LSI 550-3 and MS 550 remove 
blocks 
as shown. 
input  shaft bearing. 
9. Using Tool No. 550-1 fit layshaft  bearing,  with 
6,5-7 mm of bearing  protruding  from front  of 
bearing  plate. This allows  easier assembly 
of the 
layshaft  and mainshaft  at a later  stage. 
2 
ST1344M 
9 
ST1347M 
10. Fit circlip  to input  shaft bearing. 
11. With  the front  bearing  plate still warm fit input 
shaft  bearing,  using 
Tool Nos. LST 550-3 and MS 
550. 
3. Remove  circlip from bearing. 
4. Remove  layshaft front bcaring  from bearing  plate 
using 
Tool No. LSI550-1. 
ST1345M 
5. If necessary,  replace bearing  plate dowels. 
6. Clean  bearing  plate, gasket  forces and input  shaft 
7. Using  an air  line  blow  out oil-way in bearing  plate. 
8. Heat front  bearing  plate to facilitate  refitting of 
and 
layshaft  bearing seatings. 
input  shaft and layshaft  bearings. 
ST1346M 
73  
						

							37 
Front cover and oil pump 
1. Remove  cover plate,  drive gear and impellor  gear. 
2. Remove  cover plate ‘0’ ring. 
3. Position  wooden blocks under front cover  and 
remove  oil feed  ring and 
oil seal. 
LT85 FIVE SPEED GEARBOX 
W 
ST1348M 
4. Clean  all front  cover  componcnts. 
5. Lubricate  lip of new oil seal and position in front 
6. Fully  seat oil seal in position  using suitable  tube. 
7. Fit oil feed  ring,  ensuring  the three  holes of the 
feed ring are at the  bottom  and the ccntrc hole is 
aligned  with the mating  oil pump  feed drilling 
in 
the front  cover. 
cover 
seating  with close  side downwards. 
6. Fully scat feed ring in position  using suitable  tube. 
9. Fit cover plate ‘0’ ring, lubricate  and fit impellor 
10. Fit cover plate,  ensuring  chamfer of centre  hole is 
gear, 
and drive  gear. 
facing  towards 
oil pump. 
74 
Gearbox  extension housing 
1. Remove rear oil seal  from  extension  housing using 
2. If necessary,  replace extension  housing dowels. 
3. Clean gasket faccs and interior  and extcrior 
4. Using Tool No. LS7’ 102 fit new oil seal  to 
suitable 
drift. 
surfaces. 
ex 
t e n sio n ho  usi  ng . 
4 
lop  Cover 
1. Clcan top cover  gasket  faccs and interior  and 
2. Remove  top filler  plug,  clcan,  apply sealant  and 
exterior 
surfaces. 
refit  plug. 
Bias spring  housing and lower  gear lever 
1. Fit housing  to vice  and remove  bias spring 
adjusting 
Screws r 1d 
STl350M 
2. Clean  lower gear levcr and nylon  cup. 
3. Clean  housing,  adjusting  screws, bias spring  bores, 
4. Refit  bins  spring screws - two turns only at this 
_-. springs  and shims. w: “$1’ 
stage.  
						

							LT85 FIVE SPEED GEARBOX 1371 
f. I... . s, Bell housing ;.:?:,*i _!.. .,, . .  . 7, 1. Remove clip retaining  thrust bearing  carrier to 
2.  Withdraw  thrust bearing  and carrier  assembly  from 
3.  Remove  bolt and spring  washer  securing  operating 
4.  Remove  operating  lever and pivot  slotted  washer. 
5. Remove  operating  lever pivot. 
6. Unscrew  single bolt and remove  bearing sleeve 
clutch 
opcrating lever fork. 
sleeve. 
lever  pivot  clip 
to lever.  Remove  pivot clip. 
from  bell housing. 
6 
STl351M 
7. Rcmovc  bearing sleeve dowels, if necessary. 
8. Clean  bell housing  interior,  exterior and mating 
lstl2nd synchro  assembly 
Before dismantling 
1. Before  dismantling,  mark relationship  of synchro 
2. Fit synchro  baulk rings. 
3. Place  synchro  assembly  and baulk  rings into a 
plastic  bag 
to ensure  none of the components  are 
lost during next operation. 
hub 
to sleeve. 
4.  Press  sleevc  from hub. 
2 
ST1352M 
5. Retrieve  synchro balls, springs  and slipper  pads 
6. Clean all synchro  assembly  components. 
and 
remove  baulk ring. 
NOTE: 
Before  reassembling  the synchro  assembly, 
described  in the following  paragraphs under the heading 
Mainshaft and gear 
train. 
faces. 
bearing  carrier. 
9 grease to lever pivot and inner face Of carry out the checks for 3rd and 2nd gear end floats, as 
10. Reassemble in rcverse order. 
Input shaft 
1. Remove  4th gear  baulk  ring and needlc  roller 
2.  Clean  all components,  ensuring oil
-way on input 
3. 
Clcan input  bearing  circlip and selectivc washer. 
bearing. 
shaft  is 
blown through  with air line. 
Mainshaft 
1. Remove  shim and 1st gear  bush. 
2. Remove  1st gear,  needle  roller bearing  and bearing 
3. Remove  1st gear  baulk  ring, lst/2nd gear synchro 
4.  Remove  2nd gear  baulk  ring, 2nd gear,  needle 
5. Fit mainshaft  into vice  and remove  circlip retaining 
6. Remove  selective  washer, 3rd/4th synchro 
spacer. 
assembly 
and 2nd  gear. 
roller  spacer  and needle  roller bearing. 
3rd/4th synchro  hub and gear assembly. 
7. Fit synchro  hub to sleeve  ensuring  the alignment 
marks  match up. 
8. Place hub and sleeve  over suitable  block. 
9. With hub resting on block  adjust  height  of hub 
sufficiently  to 
fit springs. 
10. Locate slipper pads, fit springs  and press  balls 
down 
to be retained  by synchro  sleevc. 
11. 
Fit baulk  ring to hub and sleeve. 
-I 
1 6 assembly  and baulk  ring. 
7. Remove  3rd gear,  needle  roller spacer  and needle 
roller  bearing. 
8. Remove  oil seal  from  front of maimhaft. 
9. Clean  mainshaft,  and all mainshaft  components 
and  check 
for obvious  wear. Ensure oil-ways in 
mainshaft  are blown  through  with air line. 
ST1477M 
12.  Invert  synchro  assembly,  carefully, and fit second 
13. Press synchro  sleeve over hub to locate balls in 
14. Remove baulk rings. 
baulk 
ring. 
position. 
75  
						

							b 
37 
3rdl4th synchro assembly 
1. Repeat operation  as for IstRnd synchro assembly 
(omitting  the 
gear end float  checks). 
LT85 FIVE SPEED GEARBOX 
NOTE: When  reassembling 3rd/4th synchro  the 
large chamfer 
on synchro slceve faces the  small boss 
on the hub, 
5th  gear synchro  assembly 
I. Repeat operation  as for Ist/2nd synchro assembly. 
NOTE: When 
chamfer on  the reassembling 
5th  gear synchro the 
hub faces to  the rear. 
Mainshaft and gear train 
3rd  gear end  float 
1. Locatc the main  shaft in a vertical  position  as 
shown.  Fit 3rd  gear  and needle  roller bearing 
to the 
shaft  and replace  the 
3rdl4th synchro  inner 
member.  Press down  on the  synchro  inner member 
and  check 
thc gear  running  clearance with a feeler 
gauge,  as shown. 
A clearancc in excess of 0,19 mm 
(.U08 in)  indicates  that the thrust  laces arc wcrn 
and may  be the  cause  of gear  noise or transmission 
back  lash. New 
or little worn  components  will 
usually  have 
a clearance of between  0,075 mm and 
0,125 
mm (.003 in to .OM in). 
ST 
3rdl4th synchro  end float 
2. Maintain  the mainshaft in a vertical  position  as 
shown. 
Fit 3rd  gear  needle  roller bearing,  spacer, 
3rd  gear,  baulk  ring and synchromesh  with the 
large  area thrust  face towards  3rd gear  and the 
chamfer  on the  outer  member  towards 
thc front. 
76 
STl354M 
*2 
Next fit the original  selective  washer  and  retain 
with  the circlip.  Check the clearancc  between the 
washer  and the synchro  hub which  must not exceed 
0,075 
mm (.U03 in). The condition  is ideal  when 
the  selective  washer can be 
just turned  by hand, 
i.e.  minimum  end float.  Finally  secure components 
with 
a new  circlip. 
Oil seal 
3. Renew oil seal in the  front of the main  shaft at this 
stage  then invert  the shaft  ready 
for assembly of the 
rear  end. 
2nd gear  end float 
4. Fit 2nd gcar  needle  roller bearing,  spacer, 2nd gear 
and synchromesh  inner member with thc selector 
groove  towards  the rear  as shown. 
Press down  on 
the  synchro  inner member  and 
check 2nd gear  end 
float  tolerance  which 
is identical to 3rd  gear 
previously  described. 
I I ST1539M  
						

							~~85 FIVE SPEED GEARBOX 1371 
.:i : . i.; ..., -;.::. ..:, ..:.?:, , ... .. .. ... , 
1st gear to bush end float  5th gear end float 
7. Fit 5th  gear  thrust  washer,  5th gear,  needle  bearing 
and  spacer  followed  by synchromesh  unit but 
leaving  out the baulk  ring at this  stage.  Press down 
on the synchro  inner member  and chcck the gear 
end 
float as  shown; this tolerance,  again is identical 
to  3rd  gear. 
5. To carry out 1st gear  check,  it is  not  necessary to 
assemble  the components  on to the mainshaft. 
Assemble  1st gear 
on to the  bush  and using  a 
suitable  straight edge 
or flat plate  (the oil pump 
back  plate 
is ideal)  check  the end  float of 1st gear 
on the bush  as shown. The tolerance  is identical to 
.. .. 
I. 
S7 
3rd  and  2nd  gear  end floats. 
-1 540M 
lsthd synchromesh end float 
6. Next fit the 1st gear  baulk  ring, 1st gear bush  and 
gear,  original  selective  washer, dummy bearing 
LST 101 and circlip  onto the shaft,  then check  the 
end 
float as  shown.  Choose  a suitable selcctivc 
shim  washer to obtain  the correct  tolerance  which 
is  identical  with 
3rd/4th synchromesh, i.e. 
minimum to 0,075 mm (.U03 in). 
.. . .. .. .. . 
STl353M 
.6 
-6 
5th gear synchro end float 
8. Fit the 5th  gear  synchromesh  backing plate, seal 
collar,  original  selective  shim washer  and circlip. 
Then check  the clearance  as shown;  select a 
suitable  shim washer  to minimise  the clearance. 
I his adjustment  is identical to the lst/2nd and 
3rd/4th synchromesh  units. 
With  all 
thc mainshaft  adjustments  correct, remove 
the  5th  gear  componcnts  ready 
for assembly. 
?. 
5th gear selector fork and bracket assembly 
1. Remove slipper pads from  selector  fork and check 
2. If necessary,  remove circlips and remove  selector 
3. Clean all componcnts  and refit  in reverse  order. 
for wear. 
fork  pivot  pins. 
77  
						

							37 
Lay shaft  REASSEMBLING GEARBOX 
1. Remove layshaft rear bearing  inner race. 
2. Fit layshaft  to vice  and lever off front  bearing  inner Input shaft,  mainshaft  and layshaft 
track. 1. Position  front bearing p!ate on suitable  stand and 
fit input shaft into bearing. 
2 
LT85 FIVE SPEED GEARBOX 
SI 
3. Clean  layshaft,  bearings  and tracks and check for 
wear. 
2. Secure  bearing  plate in vice, fit original  selective 
washer  and retain  with 
circlip. 
3. Measure  the clearance  between washer and input 
shaft  bearing. 
If a measurcmcnt in excess  of 
0,075 
mm is  obtained  remove circlip and washer. 
4. 
Fit  layshaft  front bearing  track. 
5. Fit rear bearing  race to layshaft,  ensuring  the 
identification  numbers etc., 
of the bearing  are 
facing  forwards. 
NOTE: Inner tracks  are  offset  and  the  bearings 
must 
be fitted  with narrow shoulders together. 
Reverse  idler gear  assembly,  shaft and lever 
1 Secure  reverse  gear in vice and iemove circlip 
retaining  bearings 
2 
ST1357M STl359M 
2. Remove  upper thrust  washer,  two needle  roller 
3. Invert reverse  gear and remove  second circlip. 
bearings 
and lower  thrust  washer. 4. If necessary, - - IC~IIUVC spiit piin and withdraw siipper 
5. Press out reverse  lever cross  link operating  pin, if 
6. Clean all components and check for wear. 
7. Lubricate  needle roller bearings  and reassemble 
reverse  idler gear  assembly  and lever 
in reverse 
order.  pads 
and washer 
from reverse  gear lever. 
necessary. 
78 
3. Selcct  and measure  new washer to takc up the 
5. Fit new selective  washer and retain  with circlip. 
6. Recheck to ensure a running  clearance  of 
0,075 
mm is  obtained  between washer and bearing. 
8. Lubricate  mainshaft  pilot bcaring  and fit to input 
9. Fit 4th gear baulk  ring to input shaft. 
excessive 
running 
ciearance. 
7. Position front bearing  plate on suitable  stand. g-:: I .L t., ,, shaft.