Land Rover Defender Workshop 1993 Rover Manual

2. Using service  tool 18G 705 and 18G 705-1A 
withdraw  the 
oil seal  collar. 
LT77S MANUAL GEARBOX 
MAINSHAFT AND LAYSHAFT FIFTH GEARS 
1. Remove  mainshaft 0 ring. 
2. Remove oil pump drive shaft. 
3. Remove E clips from  selector  fork. 
4. Remove  fifth gear  selector  spool. 
5. Remove selector  fork  bracket. 
3. Remove the fifth gear extension  housing. 
4. Secure  the  centre  plate to the gearcase with 
two 8 x 35mm  bolts. 
6. Locate flange  holder tool 18G 1205. 
7. Fit  manufactured tool A...

LT77S MANUAL GEARBOX 
9. Remove  circlip retaining  mainshaft  fifth gear 
synchromesh. 
10. Fit  special tool 18G  1400-1 and  18G  1400  as 
illustrated. 
CAUTION: ensure  the puller  feet locate  in the  two 
cut-outs 
in 18G 1400-1 and between  the pins. 
11. Remove  fifth gear  synchromesh. 
12.  Remove  layshaft fifth gear  using  special 
tools 
18G 705 and 18G  705-1A.  

Main gear  case. 
1. Secure  reverse  shaft retainer,  manufactured 
tool 
A, to centre plate 
2. Fit  studs,  manufactured  tool B to gear  case. 
LT77S MANUAL GEARBOX 
5. Remove  front cover  and gasket. 
6.  Retrieve  selective washers. 
7. Remove  bolts and lift-off gear case. 
8. Secure  centre plate with nut and  bolt. 
3. Invert  gear case  and locate  studs in 
workstand  holes. 
4. Remove selector shaft spool retainer.  

LT77S MANUAL GEARBOX 
REVERSE SHAFT, LAYSHAFT  AND MAINSHAFT 
1. Remove  retainer (tool A) and reverse  shaft. 
2. Remove  thrust washer,  reverse gear and 
spacer. 
3. Remove  reverse lever pin with E clip 
attached. 
4. Remove  lever and slipper  pad. 
5. Remove  input shaft and fourth  gear baulk  ring. 
6. Remove  layshaft by tilting,  as illustrated  and 
lifting  mainshaft. 
7. Unscrew  plug and remove  spring and 
outboard  detent 
ball. 
8. Align fifth gear  selector  pin with  centre  plate...

LT77S MANUAL  GEARBOX 
12. Using  extractor  tool 18G  705 and collets  18G 
705
-7,  withdraw  layshaft bearings. 
DISMANTLE MAINSHAFT 
1. Remove  circlip retaining  first gear  assembly. 
11.  Collect  inboard  detent ball and  spring  from 
centre  plate. 
2. Remove  taper bearing,  bush, needle  bearing, 
first  gear  spacer,  cone, inner and outer  baulk 
rings. 
3.  Remove  circlip to release  first and  second 
gear  synchromesh  assembly.  

LT77S MANUAL GEARBOX 
5. Remove first and second  synchromesh  baulk 
rings. 
6. Using MS 47 and  support  bars  under second 
gear,  press 
off pilot bearing,  third,  fourth 
synchromesh  second and third gear  assembly. 
4. With MS 47 press  first gear  assembly from 
mainshaft. 
7. Remove  washer, third,  fourth  synchromesh, 
third  gear  baulk  ring, split  needle  rollers, bush, 
needle bearing  and second  gear. 
8. Remove  snap  ring,  spacer, second  gear  cone 
and  circlip.  

LT77S MANUAL GEARBOX 
GEARBOX CASINGS AND OIL PUMP 
Degrease  and clean  all components  and discard 
gaskets  and seals. 
Gearbox  casing 
1. Remove mainshaft  and layshaft  bearing 
tracks. 
2. Remove  plastic scoop from inside  the casing. 
Centre  plate 
1. Remove bearing tracks. 
2. Inspect  for damage  and selector  rail bore  for 
wear. 
3. Temporally fit reverse  shaft gear and lever 
and  check  clearance  between slipper and 
lever  does not exceed 
0,20 mm (0.008 in). 
Extension case 
3....

LT77S MANUAL GEARBOX 
3. Check oil pick  up  pipe  for obstruction  but do 
not  remove. 
4.  Remove  drain plug assembly.  Clean  and 
renew  filter and washers 
if necessary. 
5. Renew  oil seal. 
6. Renew  Ferrobestos bush. 
WARNING:  This bush  contains  asbestos. Do not 
attempt  to clean  it. Poisonous  substances. 
7. Fit new bush  with  drain  holes  towards bottom 
of casing. 
CAUTION: If drain holes  are not  positioned 
correctly  oil may  build  up behind 
oil seal  and 
cause  a leak. 
9....

7. Clean and examine  all  components  and renew 
where  necessary. 
8. Assemble  above  parts in reverse  order using 
multi
-purpose  grease on gear  lever. 
NOTE: Ensure  spring loaded  pad is properly 
located  and that  the lever  is fitted  to the  housing 
with  the pad  on the  opposite  side to the  bias 
spring.  Leave bias spring  adjusting  screws slack 
until  assembly 
of gearbox. 
Remote  gear lever  housing. 
1. Release  socket  headed  screw to remove 
2. Remove circlip to release...

10. Remove circlip to release  rollers and pin from 
quadrant. 
11. Clean and examine  all components  and renew 
where  necessary. 
12.  Assemble  housing 
by first fitting “O” ring to 
shaft. 
13. Fit quadrant  and secure  with roll pin. 
14. Fit rollers  and secure  with circlip. 
15. Fit fifth  gear  spool  retainer  and apply  Loctite 
290  to bolt  threads. 
16.  Apply  Loctite  290 
to reverse  switch threads. 
17. Fit seating  to trunnion  and secure  with circlip. 
18. Fit trunnion to shaft  and...