Land Rover Defender Workshop 1993 Rover Manual
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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 and spacer to restrain layshaft fifth gear. 8. De-stake and remove fifth gear nut.
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 slot. 9. Remove mainshaft, gears, selectors and forks. 10. Remove selector fork assembly from gears.
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. Inspect case for damage, cracks and stripped threads. 1. Examine for damage to threads and machined 4. Fit a new scoop with scoop side towards top of casing. 2. Remove oil pump cover, inspect gears and faces. housing and renew if required. Front cover 1. Remove oil seal from cover. Do not fit a new seal at this stage
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. Fit oil seal to housing, lip side leading, using 18G 1422. Apply SAE 40 oil to lip. 10. Assemble gears to oil pump and fit cover. 8. If extension housing is being renewed transfer grub screw to new housing. Apply Loctite to threads. GEAR CHANGE HOUSING 1. With a length of tube, release the bias spring from adjusting screws. 2. Remove bias spring adjusting screws.
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 seating from 3. Remove fifth gear locknut and stud. trunnion. trunnion. 3. Drive-out roll pin to remove bias spring. 4. Remove reverse gear plunger and shim. 4. Remove gear lever extension from lower gear lever. 5. Remove bolt and special washer to remove lower gear lever. WARNING: Hold the nylon spring loaded pad while removing the lever to prevent it causing personal injury. 6. Remove gear selector housing from remote housing. 5. Remove fifth gear spool guide. 6. Remove blanking plug. 7. Drift-out roll pin securing quadrant to shaft. 8. Withdraw selector shaft through hole. 9. Remove selector shaft “O” ring.
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 apply Loctite to retaining screw threads. 19. Fit reverse gear plunger and original shims. 20. Fit fifth gear stud stop and locknut. 21. Fit new bucker plug with Hylomar PL 32. 22. Fit gear selector housing to remote housing.