Land Rover Defender 90 110 Workshop 1984 Rover Manual

							LT85 FIVE SPEED GEARBOX 
,.._ .. . . .... ,:,:.,i., .. .. 10. Lower mainshaft  assembly into input shaft at the 
same  time rotating  to engage  baulk 
ring slots and ., ;- , ., . , .. 
lugs. 
I 1. Engage  3rd gear. 
12. Fit layshaft  assembly  to front  bearing  plate and 
mesh with mainshaft. 
37 
15. Fit guide studs 18G 1294 to gearbox. 
NOTE: Take  care to ensure  that the front  layshaft 
bearing  rollers are not  put out of alignment,  then 
return 
3rdl4th synchro  hub to neutral. 
ia 
-1 2 
ST1361M 
Gearbox  case and reverse  shaft 
16. Fit new gasket  on front  bearing platc. 
17. Lower  gearbox  case over mainshaft/layshaft 
asscmblics  using guide  studs to locate  front bearing 
plate. 
18. Fit tube, Tool No. LST 1431-1  over  mainshaft and 
locate on rear bearing. 
19. Fit Tool No. 18G 1431  over  mainshaft  and locate 
on  other 
tool. 
20. With  assistance, to prevent  gearbox  and mainshaft 
rotation,  and using  above  tools, 
pull gearbox  to 
front  bearing  plate. 
12 
ST1358M 
13. Remove  the rear  bearing  circlip and dummy 
.. bearing. 
Reverse  gear 
14. Fit thrust washer to reverse  gear, chamfer  towards 
gear,  locate  gear in gearbox  case, and retain 
temporarily 
in position  with a screwdriver,  or 
similar  implement. 
1 .. 
19 
8 
. 
I J 
/I7 
@ 
ST1362M 
79  
						

							. 
37 LT85 FIVE SPEED GEARBOX 
21. Fit layshaft rear bearing  (identification  numbers to 
rear)  dummy  spacer, and 
rctain temporarily with 
layshaft nut. 
22. Remove  guide studs 18G 1294. 
23.  Temporarily 
fit two  bell housing  bolts with spacers, 
to  secure  front bearing  plate to gearbox. 
24. Remove Tool Nos. 18G 1431 and LST 1431-1 and 
then  check  that 
the mainshaft  is engaged  through 
bearing  sufficiently 
to fit mainshaft  bearing circlip. 
25. Remove  screwdriver  from reversc shaft location 
and 
fit reverse  shaft. 
26.  Invert  gearbox  and 
fit spacer to layshaft  front 
27. Using Tool Nos. LS’I‘ 550-1 and MS 550 locate 
bearing. 
layshaft 
front bearing  to final  position. 
27 
ST1364M 
28. Temporarily  remove layshaft  bearing spacer. 
29.  Refit  gcarbox  stand (manufactured  tool) 
to 
underside of gearbox and secure  with two bolts, 
nuts,  spring  and plain  washers.  Adjust bolt 
undes 
filter housing  as necessary. 
30. Secure  gearbox  stand in vice. 
31.  Check  that 
4th gear baulk ring and all other  baulk 
32. 
Fit layshaft  front bearing  spacer. 
33. 
Fit new  gasket to front  cover. 
34.  Tape  input shaft splines,  to prevent 
damagc to 
80 
rings  are free. 
front  cover  oil seal 
in next  operation.  35. 
Ensure 
oil pump  drive aligns with the square 
seating 
in the  layshaft  and fit front  cover to front 
bearing  plate and secure 
with seven  bolts and 
spring  washers. 
36.  Removc  tape from  input  shaft splincs. 
Reverse  lever, reverse shaft/bearing retaining  plate 
37. Fit reverse lever to reverse gear. 
38. Apply  Loctite  Stud and Bearing  Fit (270)  to pivot 
bolt  threads, 
fit bolt in gearbox  and locate in 
reverse  lever pivot  boss. 
39.  Position  reverse shaft, layshaft  bearing track 
retaining  plate and secure  top of plate  with 
two 
bolts and spring  washers. 
39 
40. Apply  Loctite  Stud and Bearing Fit (270)  to socket 
head  set screws  and secure  bottom  of retaining 
plate. 
5th gear,  layshaft and mainshaft 
41. Remove  nut from  layshaft  and remove  dummy 
42.  Fit 5th  gear  to layshaft  with large  boss to the  rear. 
43.  Rotate  layshaft  to give  access  to stake  slot. 
44. To facilitate  next operation,  lock gearbox  by 
45. Fit a new 5th gear  retaining  nut and  tighten to the 
46.  Stake  retaining 
nut collar into recess in layshaft. 
47.  Return 
1st and 4th synchros  to neutral. 
48. Fit mainshaft  rear bearing  circlip. 
49. Fit thrust washer. 
50. Lubricate  needle roller bearings  and fit to 
51. 
Fit 5th  gear  synchro  cone and synchro  hub 
52. Tape mainshaft splincs and fit ‘0’ ring to its seating 
53. 
Fit oil  seal  collar  and locate in peg on hub  backing 
54. Fit the washer  selected  during the 5th  gear  end 
55.  Remove  tape. 
spacer. 
engaging  1st and  4th gears. 
specified  torque. 
mainshaft  followed by spacer  and 
5th gear. 
assembly. 
on  mainshaft. 
plate. 
float  check  and retain 
with circlip.  
						

							LT85 FIVE SPEED GEARBOX 1371 
Selector rails and forks 
56. Locate 5th gear  fork and bracket on to synchro  hub 
57. Secure fork bracket to gearbox  with two bolts, 
and 
gcarbox  dowels. 
plain washers and spring washers. 
. 
59. Fit lstnnd and 3rd/4th selector forks. 
58. Fit selector rail intcrlock plungers  into the cross- 
drilling in the  gcarbox  case. 60. Fit reverse cross-over lever. 
61. Insert  interlock  into lst/hd selector rail. 
81  
						

							LT85 FIVE SPEED GEARBOX 
62. Push M2nd selector  rail through  gearbox  seating 
and  locate 
in reverse  cross-over lever  and selector 
fork; 
do not  tighten  fork clamp  bolt. 
NOTE: IstiZnd fork clamp bolt is not a set boit. 
63. Fit lst/2nd selector  jaw to rail and  align for roll pin. 
64. Using  suitable  drift, tap in roll pin to secure  jaw 
65. Repeat  operation for 3rd/4th selector rail and jaw. 
66.  Push  5th gear  selector  rail through  gearbox  scating 
67. 
Fit 5th  gear  selector jaw to rail, align  for roll  pin. 
and 
rail. 
and  locate 
in reverse  cross-over lever. 
68. Locate  selector rail into 5th gear  selector fork and 
secure  with clevis  pin, washer,  and split  pin. 
69. Fit roll pin and  secure  selector rail and jaw. 
70. Push  reverse  sclector  rail through  gearbox scating 
and  locate 
in reverse  cross-over. Do not lighten 
lever  clamp  bolt. 
71. Fit jaw to rail  and  align  for roll  pin. 
72. Using a suitable  drift, fit roll pin to secure sclccror 
rail and jaw. 
NOTE: The  roll pin must  be inserted  sufficiently  to 
be  flush  with the underside  face 
of the selector.jaw. 
72 71 I 73 
ST 1367M 
82  
						

							LT85 FIVE SPEED GEARBOX 137 I 
, ::,:+, 73. Fit reverse gate spring  to selector  rail and  knock- 
74. Fit detent balls and  springs. 
:::. .
						

							1351 LT85 FIVE SPEED GEARBOX 
Bell housing 
97. Remove  bolts and spacers  securing  front bearing 
plate 
to gearbox. 
98. Fit new bell  housing  gasket. 
99. Locate bell housing  squarely  on dowels  and 
secure  housing  and front  bearing  plate 
to gearbox 
with six bolts  and spring  washers. 
Lower  gear 
leverlbias spring  housing 
100. Removc  rag from  gearbox  top cover. 
101. Lubricate  gear lever  ball and  lower  yoke. 
102. Fit lower  gear lever,  nylon cup and grommet. 
103. Fit new  gasket  to housing. 
104. Grease  bias springs. 
105. Carefully fit shims  and bias  springs,  followed  by 
spring 
housing and  secure  with four set screws, 
and  spring  washers. 
106. Remove  gearbox assembly from vice and detach 
-stand. 
Gearbox  extension  housing 
107. The special  nut retaining the 5th gcar to the 
layshaft  must be secured  in position,  by carefully 
forming 
the collar of the nut into  the layshaft 
slots,  as illustrated. 
108. Support  underside  of gearbox  with wooden  block. 
109. Lubricate oil seal protection  sleeve Tool No. LST 
102 and fit to oil seal  from  inside  extension 
housing. 
ilG. Fit new  gasket  to extension  housing. 
11 I. Carefully  manoeuvre  extension housing over 
mainshaft  and position  squarely 
on dowels. 
CAUTION: A round nose tool must  be used  for 
this  operation  to avoid  splitting  the collar 
of the 
nut. 
Also, the  5th laygear should  be supported by a 
wooden  block when the nut 
is being  deformed,  to 
prevent  damage 
to the bearings  adjacent  to the 
gear. 
112. Remove  oil seal  protection  sleeve. 
113. Secure extension  housing to gearbox with eight 
bolts,  spring  washers  and single 
nut. 
NOTE: Illustration  shows correct  bolt lengths  and 
their  locations  in extension  housing. 
60 
45 I /n 
ST1374M 40 ST1483M 
a4  
						

							LT85 FIVE SPEED GEARBOX 1371 
3rd/4th gear selector  rail adjustment 
114.  Slacken 3rd/4th stop screw in extension  housing. 
Bias spring  adjustment 
123. Apply  Loctite  Stud and Bearing Fit (270)  to bias 
springs  screws and tighten  up until  screw  heads 
are  flush  with top face 
of bias  spring  housing. 
. _. . 
:: .:, -.i 
... , ., ;.i ,;:,’;~ ”.. ... ,,.- . .I 
123 II 
115. Select  3rd gear. 
116.  Tighten 
stop screw  until it makes  contact  with 
3rd/4th selector rail. 
117. Turn back stop Screw one turn. Retighten 124. Refit mounting  to extension  housing and secure 
locknut.  with four bolts. 
118. Return  gear lever  to neutral. 
119. Slacken  locknut on 3rd/4th stop bolt inside bell 
housing. 
Gearbox  mounting 
ST1376M ‘ 
120. Unscrew stop bolt. 
121.  Select  4th gear 
and screw in stop  bolt until  contact 
is  made  with 
3rd/4th selector  shaft. 
122. Turn back stop bolt one turn  and rctighten 
locknut. 
Return  gear lever  to neutral. 
85  
						

							37 
REMOVE LT230T TRANSFER GEARBOX 
FROM 
THE LT85 GEARBOX 
LT230T TRANSFER GEARBOX 
Special tool: 18G 1425 -Guide  studs (3) 
Also, locally  manufactured adaptor  plate, see below 
Adaptor plate 
for removing  transfer gearbox 
The transfer  gearbox  should be removed  from 
underneath  the vehicle,  using a hydraulic  hoist. An 
adaptor  plate for locating  the transfer  gearbox  onto the 
hoist  can 
be manufactured  locally to the  drawing 
below.  If a similar  adaptor  plate was made  for the 
Lr230R transfer  gearbox, it can be modified to suit 
both  the 
LT230R and LT230T gearboxes  by making  the 
modifications  shown by the  large  arrows. 
Y I 1 12.63 67.0 12.63 6x0) 1 0.56 6- 5 -4-3 165.1 
ARC WE,LD TO BS5135 
! 6.43 ! 
rl i 
I 5-52 - 13 9.7 
;r--...----, 
Material.  Steel plate BS 1449 Grade 4 or 14 
Holes  marked  thus * to be  drilled  to fit hoist being 
used. 
$ = MODIFICATION 
86  
						

							LT230T TRANSFER GEARBOX I37 I 
1. Install the vehicle on a ramp. 
2. Disconnect thc battery. 
3.  Remove  the cover  panel  from the right
-hand  seat 
4. Remove the breathcr pipe union  from the transfer 
5.  Disconnect  the 
high/low lever. 
base. 
gearbox 
high/low cross-shaft  housing.  16. 
Remove  three 
nuts and bolts  securing  the right- 
handgearbox  mounting bracket to the chassis, then 
remove  the 
nut from the rubber mounting  and 
withdraw  the bracket. 
17. Place  a suitable  wooden  block between  the indin 
gearbox and chassis  cross-member,  then lower  the 
hoist  until the gearbox  contacts  the wooden  block. 
18. Disconnect  the electrical  lead from thc differential 
lock  switch. 
19.  Move  the small  crank  lever, for 
the highhow 
selector,  upward to allow access  to the  adjacent nut 
20. 
21. 
22.  securing 
the transfer 
box to the main  gearbox 
extension  case. 
Remove 
the two  nuts  and four  bolts  securing  the 
transfer  box 
to the main gearbox  extension  case. 
Fit three guide  studs, 18G 1425, through the 
transfer  box bolt holes to support it during 
removal. 
Lower  the hoist  and withdraw  the transfer  box 
from  the vehicle. 
6. Disconnect  the transmission  brake cable at the 
7. Raise the vehicle  on the  ramp  and drain  the oil 
8. Remove  the centrc section of the  exhaust  system. 
9. Disconnect  the front and rear  propeller  shafts from 
the  gearbox  and move  them aside. 
10. Disconnect  the speedometer  cable from the 
transfer  gearbox. 
11. Remove  the split  pin at the  lower  end of the  pivot 
arm  for the  differential 
lock control.  Then, rcmove 
the two bolts securing  the pivot  arm to allow  the 
link to be  disconnected. 
12. Manufacture  an adaptor  plate in accordance  with 
the  drawing,  to attach 
to the  gearbox  hoist and 
transfer  box to facilitate  removal 
(RR244M). 
13. Place four, 30 mm (1.250 in) long  spacers  between 
the top ef the hoist  and the adapter p!ate at the 
securing  points and secure  the adaptor  plate to the 
hoist. 
14.  Remove  the four  central  bolts from  the transfer 
box  bottom  cover, move the hoist  into position  and 
secure  the adaptor  plate 
to the transfer  box. 
15.  Adjust  the hoist 
to take  the weight  of the  transfer 
box.  clevis 
joint. 
from  the transfer  box. 
. ,. .. .. 
, : ,. . .. .. 
Refitting 
23. Make  sure that the joint  faces  of the  transfer  box 
and  main  gearbox  extension  case are clean  and that 
the  three  guide  studs, 
18G 1425, arc fitted  to the 
extension  case. 
24. Lubricate the oil scal in the joint  face of transfer 
box,  secure  the transfer  box to 
the adaptor  plate on 
the lifting hoist and raise the hoist  until the transfer 
box  can be located  over 
the guide studs. 
25.  Remove  the guide  studs and secure  the transfer 
box  to the  main  gearbox  extension  case. Tighten 
the 
nuts and  bolts  to the corrcct torque. 
26.  Complete 
the refitting procedurc by reversing  the 
removal  sequence,  noting 
the iollowing important 
points. 
27.  After  removing  the lifting  hoist and adaptor  plate 
from 
the transfer  box, clean  the threads  of the  four 
bolts  for the  transfer  box bottom  cover, coat them 
washers.  Tighten to the  correct  torque. 
the  oil 
level plug  hole. 
main  gearbox.  Use the correct  grade oil. 
as  necessary. 
\,xdjth Lectitc 290, 2nd fit them tegethcr with snrinu Y a b 
28.  Refill  the transfer  box with  the correct  grade oil to 
29. Check,  and if necessary  top up, the oil level in the 
30. 
Check the  operation  of the  handbrake and adjust 
87  
						

							- 
37 
88 
LT230T TRANSFER BOX