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 
12.  Fifth gear spool  guide  25. Blanking  plug 
13.  Fifth gear stop screw  and lock  nut 
REISSUED: FEB 1993 15  
						

							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 cross  shaft. 
light  oil. Apply  Loctite  290 to plug  threads  and  12. Insert  shaft into fork  and  secure  end  cover 
fit.  with screws. 
6.  Check  that plunger  returns when depressed.  13. Fit  Nylon  seat,  groove downwards,  to  gear 
lever. 
14.  Fit gear  lever  and seat  to  cross  shaft and 
secure with  circlip. 
15.  Fit bushes  to gear  lever  and  secure  with 
clevis  pin and  split pin. 
multi
-purpose 
grease on all moving  parts. 
Transfer  gear housing. 
1. Remove  the four  screws  and  remove  gaiter 
assembly. 
2.  Disconnect the  gear lever  from selector  fork. 
3.  Retrieve the  non metallic  bushes. 
4.  Remove  circlip to release  ball  and seat  and 
withdraw  gear lever. 
5.  Remove  screws from end cover  to withdraw 
cover  and cross  shaft. 
6.  Remove selector  fork. 
7.  Remove  detent spring  and plate. 
8.  Clean  and examine  all parts  and  renew  where 
necessary. 
16 REISSUED: FEB 1993  
						

							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: FEB 1993  
						

							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  and  separate  the  two 
members. 
4.  Examine  all parts  for damage  and wear 
including wire  clips for tension. 
5.  Check  no radial  movement  exists between 
inner  members and  mainshaft splines.  (except 
fifth  gear  synchromesh). 
6.  Examine  inner and  outer  splines for wear. 
18 REISSUED:  FEB 1993  
						

							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: This applies  only to splines on selector 
groove  side of member. 
13. Assemble  third-fourth  and fifth gear 
synchromesh components as  in instruction  12. 
NOTE: The back  plate  for fifth  gear  is fitted to 
the  rear  of the  assembly  with the single  tag 
locating 
in a slot in the  inner  member. 
11. Fit inner  member to outer so that the wide 
splines 
of inner  member  are  under  the  spur 
gear  teeth. 
REISSUED: FEB 1993 19  
						

							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.  Check 
condition 
of circlip grooves. 
3.  Examine  splines for wear  and damage. 
4. Use  an air line  to check  that the main  oil feed 
from the  pump  is clear  and feed  to spigot 
bearing. 
5. Check oil feed  holes  to roller  bearings  are 
clear. 
5. Support  the shaft  under  MS 47 and  press  in a 
new  track. 
REISSUED:  FEB 1993 21  
						

							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 (0.008in). 
Second  gear end-float. 
First gear 
bush end-float. 
1. Fit needle  roller and second  gear. 
2. Fit third  gear  bush. 1. Invert  mainshaft  rear end uppermost. 
2. Fit inner  and outer  second  gear baulk  rings. 
3.  Check  clearance  between second gear and 
bush  flange.  Not to exceed 
0,20 (0.008in). 
4. Remove  above components. 
REISSUED:  FEB 1993  
						

							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 31,105/31,155 
Check first gear to bush  end-float. 
1. Fit 
roller  bearing  and bush to first gear. 
2. Place  bush flange  side downwards  on a 
raised  block on a flat  surface. 
NOTE: the block should be approximately  the 
same  diameter  as the  bush  flange 
so that the 
gear  is suspended  and does  not rest 
on the flat 
5. Fit first  gear  inner  and outer  baulk  ring. 
6. Fit cone. 
7.  Fit spacer. 
surface. 
REISSUED: FEB 1993 23  
						

							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 REISSUED:  FEB 1993