Land Rover Defender Workshop 1993 Rover Manual

LT77S MANUAL GEARBOX 
INPUT-MAINSHAFT BEARING ADJUSTMENT Mainshaft selective washers 
1. Turn gearbox  over with input  shaft  uppermost.  Part number  Thickness(mm) 
Remove  layshaft support plate. 
FRC 4327  1,51 
NOTE: Correct shimming  of the  input  shaft  FRC 4329  1,57 
bearing  is vital  to ensure  that the mainshaft  FRC 4331  1,63 
assembly  has 
the design intended  end float, and FRC 4333  1,69 
FRC  4337  1,81 
2. Measure the thickness  of a new  front  cover  FRC 4339  1,87 
the 
bearings...

LT77S MANUAL GEARBOX 
NOTE: This will ensure  zero layshaft  bearing end GEAR LEVER  AND REMOTE  HOUSING 
float and not more  than 0,025mm  (0.001in) ASSEMBLY 
pre-load once the cover  and gasket  are fitted  and 
bolts  correctly  torqued. 
3.  Remove  cover and selected  washer and 
fit 
4. Fit mainshaft  and layshaft  selected  washers to neutral position. 
1. Fit quadrant to selector shaft with new  roll pin, 
NOTE: Push  shaft forward,  fit quadrant so ledge 
is to the  left viewing box from rear....

LT77S MANUAL GEARBOX 
NOTE: If  necessary, final adjustment  can be Bias spring  adjustment 
made in vehicle.  To increase  pull-over load turn 
screw  clockwise or anti-clockwise  to reduce  load. 
Fifth  gear stop  screw adjustment. NOTE: The purpose of this adjustment is to set 
both  bolts 
so that  the bias  spring  legs apply 
equal  pressure  on  both ends 
of the gear  lever 
cross pin when  third or fourth  gear is engaged. 
This  will ensure that  when  the lever  is 
in neutral, 
distance...

LT77S MANUAL GEARBOX 
GEARS AND SHAFTS 
2. Interlock spool. 
3.  First 
- second  fork and selector  rail assembly. 
4.  First 
- second  synchromesh. 
5.  First  gear  synchromesh  outer baulk  ring. 
6. First gear  synchromesh  inner baulk  ring. 
7. Cone. 
9. First gear. 
BELL HOUSING 1. Third - fourth  selector  fork. 
1.  Fit bell  housing  locating on hollow  dowels. 
NOTE: Fit the  12 x 45mm bolts  through  dowels 
and 
12 x 30mm bolts in remaining  positions. 
2.  Apply  molybdenum  disulphide...

LT77S MANUAL GEARBOX 
REISSUED: FEB 1993 39  

LT77S MANUAL GEARBOX 
GEARBOX CASING 14. Selector plug, detent  ball and  spring. 
15. Gasket. 
1.  Front  cover.  16. 
Fifth gear  selector  bracket. 
2. Front cover  oil seal.  17. 
Fifth gear  selector fork. 
3. Front  cover  gasket.  18.  Reverse 
gear shaft. 
4. Oil drain plug  and washer.  19.  Oil pick-up 
pipe. 
5. Oil  level  plug.  20. 
Oil pump drive  shaft. 
6. Gearbox  main casing.  21. 
Oil pump  gears  and cover. 
7. Spool retainer.  22. 
Fifth gear  extension housing. 
8.  Gasket.  23....

LT77S MANUAL GEARBOX 
DATA 
Reverse lever and slipper  pad clearance  .............................  0,725 mm 
Reverse  gear plunger  operating  load ...................................  45 to 55  kg 
Synchromesh  assemblies push through  load ......................  8,2 to 10  kgf 
Clearance  between baulk rings and gears  ...........................  0,38 mm 
Fifth  gear end float  ...............................................................  0,020 mm 
Third  gear end float...

LT77S MANUAL GEARBOX 
SERVICE TOOLS 
NOTE: Where  the use of special  tools is 
specified,  only these  tools should 
be used to 
avoid  the possibility of personal  injury and or 
damage  to components. 
18G 1400  Remover synchromesh  hub and 
gear  cluster 
18G  705  Puller, 
bearing  remover 
18G 
1400-1 Adaptor mainshaft  fifth gear 
18G 
705-1A Adaptor for mainshaft oil seal 
track  and layshaft  fifth gear 
MS 
47 Hand press 
18G 
705-7 Adaptor for layshaft  bearings 
18G 
47BA Adaptor input  shaft...

18G 47BAX  Conversion kit 
18G 284  Impulse extractor 
18G 284AAH Adaptor  for input  shaft pilot 
bearing  track 
18G  1422 
Mainshaft rear oil seal  replacer 
LT77S MANUAL GEARBOX 
18G 1431  Mainshaft rear oil seal  replacer 
18G 
1205 Flange  holder 
REISSUED: FEB 1993 43  

LT77S MANUAL GEARBOX 
LOCALLY MANUFACTURED  TOOLS  Tool C. Mild steel  dummy  centre bearing for the 
In  addition  to the  special  service  tools, the following 
tools  can be locally  made to assist  the dismantling 
and  assembly  of the  gearbox.  The overhaul 
procedure  is based  upon the assumption  that these 
tools  are available. 
Tool  A. Dual purpose  tool. Reverse  shaft retainer  to 
prevent  the shaft  falling  out when  the gearbox  in 
inverted.  Also, a layshaft  fifth gear  retainer...