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 when  pressing  on the  bearing  it 
will have clamped  the first  gear  bush  preventing 
it  from  turning. 
6. Reposition  mainshaft  in vice  and using  a 
screw  driver  blade  check  that the first gear 
bush  is free  to turn. 
Third-fourth  synchomesh assembly 
REISSUED:  FEB 1993 25  
						

							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, 
4. Examine  fifth gear  selector  fork, pads  and 
5. Examine  interlock spools for wear and 
cracks 
and damage. 
pivot  pins. 
damage. 
2. Fit  the  bearings  either way round  and secure 
with  the circlip. 
3. Check  condition of idler gear  and mating  teeth 
on  layshaft  and synchromesh  outer member. 
6. Renew  retaining  circlips if distorted. 
4. Examine  idler shaft  for wear,  scores  and 
pitting. 
REISSUED: FEB 1993 27  
						

							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 
keeping  the spool  engaged 
in third-fourth  fork 
jaw. 
28 REISSUED: FEB 1993 
2. Check  both synchromesh  units are in neutral 
and  fit selector  shaft assembly. 
3. 
fit mainshaft  and selectors  to centre  plate and 
align  pin with  slot in plate.  
						

							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 slot in centre  plate. 
layshaft 
rear bearing.  A. 
12. Fit fourth  gear baulk  ring. 
13. Lubricate  spigot bearing  and fit input shaft. 
14. Remove  centre plate workstand  bolt and  fit 
REISSUED:  FEB 1993 29  
						

							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  that the centre  plate dowels  and 
selector  shaft are properly  located. 7. Remove  detent plug, apply  Loctite  290 or 
Hylomar  PL 32 to thread,  refit and  stake. 
8  Fit layshaft  and input  shaft  bearing  tracks. 
5.  Secure  centre plate and gearcase  to 
workstand  with two 8 x  35mm  bolts. 
6.  Apply  PL 32 to joint  face  and bolt threads  and 
fit  spool  retainer. 
30 
REISSUED:  FEB 1993  
						

							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  disc between  Tool 
D and layshaft. 
2. Release  and invert  gearbox  and remove 
reverse  shaft retainer  plate. 
3. With the extraction  groove uppermost,  drive 
fifth  gear  on to layshaft  using 
18G 1422. 
REISSUED: FEB 1993 31  
						

							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 
washer. 
9.  Tighten  layshaft stake nut using  18G 1205. 
CAUTION: The  practice  of locking  gears to 
provide  a restraint  to tighten  the  nut  is not 
acceptable  due to 
high torque  figure required. 
NOTE: Only  limited  movement  of the 
synchromesh  inner member  on the  main
-shaft  is 
permissable.  The maximum  clearance is 0,005mm 
to  0,055mm  (0.0002in 
to 0.002in) and to achieve 
this 
the following  selective washers are available. 
32 
REISSUED:  FEB 1993  
						

							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 clips  cover  holes 
in  centre  plate to prevent  them falling  into 
casing. 
5. Engage  tongue of spool in selector  fork. 
6. Fit oil pump  drive to layshaft. 
REISSUED: FEB 1993 33  
						

							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 mainshaft  using 18G 
1431. 
34 REISSUED: FEB 1993