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  are not  pre
-loaded.  FRC 4335  1,75 
gasket.  FRC 
4341  1,93 
3.  Place  the original  shim on mainshaft  bearing  FRC 4343  1,99 
and  finger  tighten  the bolts.  FRC 4345  2,05 
4.  Measure  the clearance  between front cover  FRC 4347  2,11 
FRC  4349  2,17 
and  gearcase 
with two feeler  gauges. 
FRC 4351  2,23 
FRC  4353  2,29 
FRC  4355  2,35 
FRC  4357  2,41 
FRC  4359  2,47 
FRC  4361  2,53 
FRC  4363  2,59 
FRC  4365  2,65 
FRC  4367  2,67 
FRC  4369  2,77 
LAYSHAFT BEARING ADJUSTMENT 
1. Place original  selective  washer on layshaft 
bearing, 
fit front  cover  without  gasket,  and 
finger  tighten  bolts. 
2.  Measure  clearance,  with 
two feeler gauges, 
between  cover and gearcase.  Select  a shim 
that  will provide  a clearance 
equal to  the 
thickness 
of the  gasket  that was  selected  and 
measured  when calculating  the adjustment  of 
5. 
IIf 
required, 
If required, change the  selective  washer to 
provide  a clearance  of 0,35mm  to 0,085mm 
(0.001  to 0.003ins)  less than  the gasket  the input  and mainshaft  bearing. 
thickness. 
NOTE: This  will ensure  that when  the gasket  and 
cover 
is fitted to the  correct  torque,  the input 
and mainshaft bearings  will have  no pre-load  and 
not  more  than 0,06mm  (0.0025in)  end float. 
6.  Remove  front cover  and keep  gasket  and 
selective  washer together. 
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							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.  Return  shaft 
new  oil seal,  lip towards  gearcase. 
and  gasket. 
2. With  a new  gasket, 
fit remote  housing  locating 
5. Wrap protective  tape round  input shaft  splines.  over dowels. 
6.  Apply  Hylomar 
PL 32 to bolt  threads  and 
secure  cover.  NOTE: Ensure  rollers locate 
in quadrant  fork. 
Layshaft  selective  washers. 
3. Fit transfer  gear change  housing. 
Part  number  Thickness(mm)  Reverse gear plunger  adjustment. 
FTC 0262  1,36  1. Fit plunger 
with original  shims and tighten 
FTC 0264  1,42  bolts. 
FTC 0266  1,48  2. Slacken  locknut, turn adjuster  screw so that 
FTC 0268  1.54  dimension “A” is approximately  12 rnm (0.50 
FTC 0270  1,60  in). Tighten  locknut. 
FTC 0272  1,66 
FTC 0274  1,72 
FTC 0276 1,78 
FTC 0278  1,84 
FTC 0280 1,90 
FTC 0282 1,96 
FTC 0284 2,02 
FTC 0286 2,08 
FTC 0288  2,14 
FTC 0290 2,20 
FTC 0292  2,26 
FTC 0294 2,32 
FTC 0296 2,38 
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							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  across corners  of locknut.  the gear  change  mechanism 
is automatically 
aligned  for third 
or fourth gear selection. 
1. Adjust  screw to protrude  from housing  the 
NOTE: This is only an  approximate  setting which 
will  limit  travel  of selector  yoke 
but will allow 
fifth  gear 
to be selected. 
1. Select  fourth gear and lift both spring  legs 
over  the cross  pins. 
2. Turn adjustment  bolts until heads  touch spring 
legs. 
3.  Apply  light pressure  to gear  lever 
to the right 
and  adjust  left hand  bolt. 
NOTE: Clearance  between  spring leg and bolt 
0,05  mm 
(0.002 in.) using  feeler gauge. 
4. Move lever to left  and  adjust  right hand  bolt to 
clearance. 
5. Tighten  locknuts. 
2. Select fifth gear.  While  applying  light pressure 
to gear  lever  towards  right, turn screw 
clockwise  until 
it contacts yoke. Turn screw 
half  a turn  anti
- clockwise  and tighten  nut. 
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							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 grease 
to pivot  8. Thrust  washer. 
post,  release  lever, socket  and push  rod. 
Not the bearing  guide.  10. Needle  roller bearings. 
3.  Fit 
C washer to pivot  post. 11. First gear  selective  bush. 
4.  Fit spring  clip to lever  and 
fit lever to pivot 
post.  13. Circlip. 
12. 
Centre  taper roller bearing. 
14.  Thrust  washer. 
NOTE: Position  spring clip behind C washer  15. Fifth gear. 
and  tighten  screw.  16. Fifth gear  baulk  ring. 
17.  Fifth gear  synchromesh. 
19.  Fifth gear  synchromesh  selective washer. 
20.  Circlip. 
21.  “O” ring. 
22. Oil seal  collar. 
23.  Snap  ring. 
24.  Fourth  gear baulk  ring. 
25.  Pilot taper  bearing. 
26.  Spacer. 
27.  Third 
- fourth synchromesh. 
28.  Third  gear baulk  ring. 
29.  Third  gear. 
30.  Third  gear bush. 
31.  Second  gear. 
32.  Thrust  washer. 
33.  Cone. 
34.  Second  gear synchromesh  inner baulk  ring. 
35.  Second  gear synchromesh  outer baulk  ring. 
36.  Mainshaft. 
37.  Input  shaft  bearing track  and selective  washer. 
38. Input shaft. 
39.  Input  shaft taper  bearing. 
40. Fourth  gear. 
41.  Selective  shim. 
42.  Taper  bearing. 
43.  Layshaft 
fourth gear. 
44. Layshaft  third gear. 
45. Layshaft second  gear. 
46.  Layshaft  reverse gear. 
47.  Layshaft  first gear. 
48.  Taper  bearing. 
49. Layshaft  fifth gear. 
50. Layshaft  fifth gear  retaining  stake nut. 
51.  Circlips 
- first  gear  and first-second 
synchromesh. 
52. Snap  ring - second  gear cone  and spacer. 
53.  Spacer. 
54. Snap  ring. 
55. Reverse  idler gear. 
56.  Thrust  washer. 
57. Snap ring. 
58.  Fifth gear spool. 
5. Fit bearing  and retain  with plastic  staple.  18. Fifth gear  synchromesh  back plate. 
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							LT77S MANUAL GEARBOX 
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							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. 
Fifth  gear  extension  housing drain  plug  and 
9.  Inboard  detent ball  and spring.  filter. 
10.  Reverse  lever and slipper.  24. Ferrobestos  bush. 
11.  Locating  dowels 
- centre plate  to maincase. 25. Oil  seal. 
12.  Reverse  lever  pivot post. 
13. Centre plate. 
40 REISSUED: FEB 1993  
						

							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  ..............................................................  0,020 mm 
Second  gear end float  ..........................................................  0,020 mm 
First  gear bush  end float  ......................................................  0,075 mm 
First  gear end float  ...............................................................  0,20 mm 
Fifth  gear synchromesh  end float  .........................................  0,005 to 0,055  mm 
TORQUE VALUES 
NOTE: Torque  wrenches  should be regularly 
checked  for accuracy  to ensure  that 
all fixings 
are  tightened  to the  correct  torque. 
Nm 
7 - 10 
7 
- 10 
7 
- 10 
7 
- 10 
7 
- 10 
22  - 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
22 
- 28 
7 
- 10 
40 
- 47 
22  - 28 
65  - 80 
22 
- 28 
47 
- 54 
65  - 80 
25  - 35 
204 
- 231 
Oil 
pump  to extension  case 
Clip  clutch  release  lever 
Spool  retainer  to gearcase 
Spool  guide 
to remote  housing 
Extension  case to gearcase 
Pivot  plate,  clutch  release 
Remote  housing to gearcase 
Gear  lever housing  to remote  housing 
Guide,  clutch release  sleeve 
Slave  cylinder  to bell  housing 
Front  cover  to gearcase 
Fifth  gear  support  bracket bolts 
Plunger  housing to remote  housing 
Gear  lever retainer 
Lower  gear lever 
to extension  nut 
Reverse  lever pivot 
post nut 
Clutch  housing 
to gearbox  bolts 
Plug,  detent  spring and ball 
Oil filter  plug 
Oil  filler 
- level  plug 
Fifth  gear  layshaft  stake nut 
Oil 
drain  plug 
Breather 
14 - 16 
7 - 10 Bottom cover to clutch  housing 
- 
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							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  bearing 
42 REISSUED: FEB 1993  
						

							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 
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							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  to hold 
the  fifth  gear  whilst  releasing  stake nut. Use  5mm 
mild  steel  to manufacture  the tool.  When  using the 
tool  for the  layshaft  nut, a suitable  spacer is required 
20mm  diameter  23mm long, with an 8mm  diameter 
clearance  hole.  selection 
of first  gear  bush. 
Tool  ‘D’. Layshaft  support plate is fitted  with two 8  x 
25mm  bolts and washers  to the  front  of the  gearbox 
case.  It also  supports  the input  shaft bearing  outer 
track. 
Tool  B. Four  pilot studs  with an 8mm  thread  for 
locating  in the  four  counter  sunk blind holes 
in the 
workstand. 
44 REISSUED: FEB 1993