Land Rover Defender Workshop 1993 Rover Manual

LT77S MANUAL GEARBOX 
CAUTION: Ensure that the slots  in the  baulk  ring 7. Position  mainshaft  in vice,  rear end 
align  with the synchromesh  slippers while downwards  and fit second gear needle  roller, 
pressing  on the  bearing. and  second  gear. 
8. Fit third  gear  bush. 
5. Invert  mainshaft  and press  assembly  back 9. Fit third  gear needle  rollers. 
against  circlip. 
10. Fit third  gear. 
11. Fit third  gear  baulk  ring. 
NOTE: Instruction 5 is necessary  since it is 
probable  that...

LT77S MANUAL GEARBOX 
REVERSE GEAR AND SHAFT 
1. Remove  one circlip from the idler  gear  and 
remove  bearings. 
12. Fit third-fourth gear synchromesh  hub. 
13. Using MS 47 with supports  under first gear, 
press  the spigot  bearing  on 
to shaft. 
LAYSHAFT 
1. Examine  the layshaft  for wear  and damage. 
2. Press  bearings  on to layshaft using MS 47 
and supporting  bars.  

LT77S MANUAL GEARBOX 
NOTE: One bearing  cage is twisted  in SELECTORS 
manufacture.  The twist  causes  the gear  to tilt  on 
the  shaft  forcing  the gear  into engagement. 
1. Examine  selector rail and  pins  for wear  and 
Renew  bearings  if worn or if the  gear  jumps  out 
2. Examine  first-second selector  fork for wear of engagement. 
damage. 
cracks  and damage 
NOTE:  The selector  rail and  fork  is only  supplied 
as  a complete  assembly. 
3. Examine  third-fourth selector  fork for wear,...

LT77S MANUAL GEARBOX 
Assembling selectors.  ASSEMBLING GEARBOX SHAFTS TO CENTRE 
PLATE 
Fitting gears to centre 
plate 
7.  Rest  first-second  fork and shaft  assembly  on 
bench  and locate  pin in jaw  of fork. 
8. Fit  interlock  spool and third-fourth  fork and 
engage  spool in jaw 
of fork.  1. 
Secure  centre plate to workstand,  fit bearing 
tracks  and inboard  detent ball and  spring. 
9. Slide  spool  and fork  towards  first- second 
selector  until slot 
in spool  locates  over pin...

LT77S MANUAL GEARBOX 
4. Fit layshaft  while lifting  mainshaft to clear 10. Secure  reverse  shaft with manufactured tool 
5. Turn  selector  shaft and interlock  spool to 11. Fit reverse  gear thrust  washer to shaft. 
allow  reverse  lever 
to engage spool flange. 
6. Fit reverse  lever to pivot post and secure  with 
pin  and  circlip. 
7. Fit slipper  pad to lever.  gasket. 
8.  Fit reverse  gear shaft,  spacer  and gear. 
9.  Fit slipper  to 
reverse gear and ensure  roll pin 
in shaft  engages in...

LT77S MANUAL GEARBOX 
FITTING GEARBOX CASING 
1. Turn selector  shaft and spool to neutral 
2. Fit out-board  detent  ball and  spring  and 
position. 
secure 
with plug. 
CAUTION:  Do not  use  force  to fit  retainer. 
Provided  the spool  has not been  disturbed  the 
retainer  will slide  into position.  If not,  remove  the 
gear  case  and reposition  spool or shaft. 
3.  Fit guide studs to casing  and check  oil scoop 
is  correctly  fitted. 
4.  Without  using force,  fit gearcase. 
NOTE:  Ensure...

LT77S MANUAL GEARBOX 
FITTING FIFTH GEAR 
CAUTION: Since the fifth  gear  is a tight  fit on  the 
layshaft,  the force,  when pressing  the gear,  must 
not  be transferred  to the  layshaft  front bearing. 
Tool 
D and  packing  disc should  be made  to the 
dimensions  given to absorb  the force.  The plate 
also  retains  the input  shaft bearing  outer track. 
4. Fit a new  stake  nut but do not tighten. 
5. Fit fifth  gear  assembly  to mainshaft. 
1. Secure  Tool D with two 8x25mm  bolts. 
Insert...

LT77S MANUAL GEARBOX 
6. Press fifth gear synchromesh  assembly to Part number  Thickness 
mainshaft  using 18G 1431. 
FRC 5284 
5,10 
CAUTION: Before  pressing  the assembly  fully  FRC 5286  5,16 
home,  ensure  that the slipper 
pads locate  in the  FRC 5288  5,22 
baulk  ring slots. 
FRC 5290  5,38 
FRC  5292 
5,34 
FRC 5294  5,40 
FRC  5296  5,46 
FRC 5298  5,52 
FRC  5300  5,58 
FRC  5302  5,64 
7.  Fit the  thinnest  washer and secure  with circlip. 
8.  Measure  clearance  between circlip and...

LT77S MANUAL GEARBOX 
10. Secure tool “A“ to gear and gear  case  and 
using  a suitable  torque wrench  tighten the 
nut 
to the correct  torque. 
FIFTH GEAR SELECTOR FORK ASSEMBLY 
1. Fit fifth  gear  selector  fork bracket. 
2. Fit the  fifth  gear  spool  long end towards 
centre  plate. 
11. Using a round  nose punch,  form the collar  into 
the  layshaft 
slots. 
3. Fit slippers to selector  fork. 
4. Fit fork  to synchromesh  and secure  with pins 
and 
“E” clips. 
NOTE: Before  fitting pins and...

LT77S MANUAL GEARBOX 
EXTENSION CASE 
1. Release  centre plate from workstand  and fit 
gasket  on joint  face. 
2.  Fit extension  case while  aligning  oil pick
-up 
pipe.  Remove  guide studs and secure  to main 
case. 
NOTE: Do not  use  farce, if necessary  remove 
case  and re-align 
oil pump  drive if case does  not 
fit  first  time. 
CAUTION: 
To protect  O ring while  fitting,  cover 
mainshaft 
splines with  smooth tape. 
3. Fit O ring to mainshaft  groove. 
4.  Fit “O”  ring collar  to...