Land Rover Defender Workshop 1993 Rover Manual

LT77S MANUAL GEARBOX 
GEAR SELECTOR  HOUSING - MAIN GEARBOX 
1. Gear  selector  housing  14. Reverse  gear plunger 
2.  Gasket  15. Gear lever  seating 
3.  Roll  pin  16. Trunnion 
4.  Bias  spring  17. Circlip 
5.  Gear  lever retaining  screw and washer  18. Trunnion retaining  screw 
6.  Selector  housing screws  19.  0 ring 
7.  Gear  lever  20. Selector  shaft 
8.  Nylon  pad and spring  21. Quadrant 
9.  Gear  lever extension  22. Roll pin 
10.  Remote  housing  23. Rollers 
11.  Gasket  24. Pin...

LT77S MANUAL GEARBOX 
Reverse gear plunger  assembly.  NOTE: Assemble the housing  using 
1.  Remove  plug spring  and ball. 
2.  Remove  circlip to release  plunger and spring.  9. Fit  internal  and external 
O rings  to fork 
3.  Clean  and examine  components.  assembly. 
4.  Assemble  plunger  and spring  with  10. Fit detent  spring. 
multi
-purpose  grease and secure  with circlip.  11. 
Fit O  rings  to end  cover  and  fit to  short  end 
5.  Lubricate 
and fit detent  ball and  spring  with  of...

LT77S MANUAL GEARBOX 
GEAR SELECTOR HOUSING - TRANSFER 
GEARBOX 
1.  Gaiter  retaining  Screw - 4 off.  11. Cross  shaft. 
2.  Gaiter.  12. Gear  lever. 
3.  Gaiter  support  plate.  13. Gear  change  housing. 
4.  Gate  plate.  14. Non
-metallic  bushes. 
5.  Gasket.  15. Counter  sunk screws. 
6.  Split  pin.  16. End cover. 
7.  Clevis  pin.  17. Detent  spring and plate. 
8.  Circlip  retaining  Nylon seat.  18. Selector  fork. 
9.  Gear  lever ball.  19. O” rings. 
10.  Nylon  seat. 
17 REISSUED:...

LT77S MANUAL GEARBOX 
SYNCHROMESH ASSEMBLIES 
Third-fourth  and fifth  gear  synchromesh. 
NOTE:  The above  assemblies  are the  same 
except  that fifth  gear  synchromesh  has a retainer 
plate. 
1.  Mark  relationship  of inner  and  outer  members. 
2.  Remove  wire  clip from  both  sides  of 
assembly. 
7. Examine  the dog  teeth  on all gears  for wear 
and  damage. 
NOTE: Example A shows  a tooth  in good 
condition.  Example 
B shows the rounded 
corners  of a worn  tooth. 
3. Remove  slippers...

LT77S MANUAL GEARBOX 
First-second synchromesh 12. Fit the  slippers  and secure  with a s 
side  of the  synchromesh. 
8.  Repeat  instructions  1 to  6 for  third-fourth 
synchromesh. 
NOTE: The  hooked  end of each spring  must 
9. Examine step  in each of outer  splines.  locate in the same slipper with the free  ends 
10.  Check  that the step  on both  sides  of the  running  in opposite  directions  and resting 
internal  splines are  sharp  not rounded.  against the remaining  slippers. 
NOTE:...

LT77S MANUAL GEARBOX 
CHECKING BAULK RING CLEARANCES 
Check clearance of all baulk  rings and gears  by 
pressing  the baulk  ring against  the gear  and 
measuring  the gap,  The minimum  clearance  should 
be  0,38mm  (0.015in). 
First gear  

LT77S MANUAL GEARBOX 
INPUT SHAFT 6. Using  Press  MS 47, Collets  18G 47B and 
adaptor  18G 47 BAX  fit a new  taper  bearing. 
1. Examine  the gear  and  dog  teeth for wear  and 
damage. 
2.  Polish  oil seal  track  if necessary. 
3.  Using  18G 284 AAH  and 18G  284 remove 
pilot  bearing  track. 
4. Using 18G 47BA  and MS 47 remove  taper 
bearing. 
NOTE:  Ensure  that the bearing  is supported  by 
the  lip inside 
18G 47 BA. 
MAINSHAFT 
1. Examine bearing journals  for wear  and scores. 
2....

LT77S MANUAL GEARBOX 
MAINSHAFT GEAR END FLOAT CHECKS  Third 
gear end-float. 
1. Hold  mainshaft  in vice  front  end downwards. 1. Fit needle  roller to third  gear. 
2. Fit front  circlip  for first-second  synchromesh. 2. Fit third  gear  bush  to third  gear. 
3. Fit second  gear cone. 3. Place  gear on flat  surface,  bush flange 
4. Fit spacer.  downwards, 
and with  a straight  edge across 
5. Fit snap  ring.  gear 
check  clearance  between straight edge 
and  gear.  Not to exceed 
0,20...

LT77S MANUAL  GEARBOX 
3. Fit first-second  synchromesh  hub, fork groove 8. Fit first  gear  bush. 
4. Fit circlip.  10. 
Fit circlip. 
uppermost. 
9. Fit 
dummy  bearing. 
11. Check clearance  between dummy bearing  and 
bush. 
Not to  exceed  0,75mm  (0.003in). 
12.  Remove  circlip, dummy  bearing and bush. 
First-second  synchromesh  assembly 
Selective first gear  bush 
Part number Thickness 
FTC2005 30,905/30,955 
FTC2006 30,955/31,005 
FTC2007 31,005/31,055 
FTC2008 31,055/31,105 
FTC2009...

LT77S MANUAL GEARBOX 
3. Place straight  edge across  gear and check 
clearance  between gear and straight  edge. Not 
to exceed  0,20mm  (0.008in). 
ASSEMBLING  MAINSHAFT 4. Fit the  taper  bearing  to mainshaft  using MS 
47, collets  18G 47 BA  and  adaptor  18G 47 
1. With  the first-second  synchromesh  hub and  BAX. 
spacer 
in position,  assemble  the rear  end of 
the shaft. 
2. Fit the  roller  bearing  and bush  to first  gear. 
3.  Fit first  gear  to mainshaft. 
First  gear assembly 
24...