Land Rover DEFENDER LT77S User's Manual
Contents
1. gt DEFENDER 90 110 130 7 4 th JM 542 DEFENDER 17775 GEARBOX WORKSHOP MANUAL SUPPLEMENT Publication Number SLR 621 WS 2 Published by the Land Rover Technical Publications Department of Lode Lane TAND Solihull West Midlands 892 8NW lt ROVER England Copyright Land Rover 1991 37 MANUAL GEARBOX CONTENTS Page OVERHAUL BIET Hzc 1 GEAR SELECTOR HOUSING 1 EXTENSION HOUSING e 2 MAINSHAFT AND LAYSHAFT FIFTH GEARS EE 3 REVERSE SHAFT LAYSHAFT AND D DISMANTLE MAINSHAFT ae 7 GEARBOX CASINGS AND OIL PUMP Ae 8 GEAR CHANGE HOUSING 10 GEAR SEEEGTOR HOUSING unntakene 12 SYNCHROMESH ASSEMBLIES 15 CHECKING RING 17 INPUT 18 Eeer dee EE dee 18 MAINSHAFT GEAR END FLOAT CHECKS 19 ASSEMBLING MAINSHAFT ae 21 EAYSHAFT ee EE 23 REVERSE GEAR AND SHAFT 23 SELECTOR c 24 ASSEMBLING GEARBOX SHAFTS TO CENTRE PLATE 25 FITTING GEARBOX CASING e 27 FITEING EIFTH GEAR AE OA 28 FIFTH GEAR SELECTOR FORK ASSEMBLY 30 EXTENSION CASE dundrer 31 INPUT MAINSHAFT BE2. Measure clearance between circlip and washer ON ST2499M 9 Tighten layshaft stake nut using 18G 1205 CAUTION The practice of locking gears to provide restraint to tighten the nut is not acceptable due to high torque figure required OVERHAUL 29 37 MANUAL GEARBOX 10 Secure tool A to gear and gear case and using suitable torque wrench tighten the nut to the correct torque ST2500M 11 Using round nose punch form the collar into the layshaft slots IN ET 2 EN 28 DEFENDER FIFTH GEAR SELECTOR FORK ASSEMBLY 1 Fitfifth gear selector fork bracket 2 Fitthe fifth gear spool long end towards centre plate D AN NN 4 Al a 2 ST2509M 1 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 AN 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 ST2510M 30 OVERHAUL LT77S MANUAL GEARBOX EXTENSION CASE 1 Release centre plate from workstand and fit gasket on joint face 2 Hit extension case while aligning oil pick up pipe Remove guide studs and secure to main case NOTE Do not use force if necessary AN remove case and re align oil pump drive if case does not fit first time CAUTION To protect O ring while fitting cover mains
3. ST3246Mi N DISMANTLE MAINSHAFT 1 Remove circlip retaining first gear assembly ST3230M 4 With MS 47 press first gear assembly from mainshaft aN ie NE II ST3227M e 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 TETT Sct OVERHAUL 7 37 MANUALGEARBOX 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 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 ST3234M DEFENDER 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 9 SZ 3 Inspect case for damage cracks and stripped threads 4 Fit new scoop with scoop side towards top of casing ST2313M Front cover 1 Remove oil seal from cover Do not fit a new seal at this stage f ST2322M e EO 8 OVERHAUL 1775 MANUAL GEARBOX Centre plate 3 Check oil pick up pipe for obstruction but do not remove 1 Remove bearing tracks
4. ST3265M 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 screw driver blade check that the first gear bush is free to turn 004091 D ZS 2 ST3233M ST3256M 4 Third fourth synchomesh assembly Sow 22 OVERHAUL LT77S MANUAL GEARBOX 0 0 12 Fit third fourth gear synchromesh hub LAYSHAFT 13 Using MS 47 with supports under first gear press the spigot bearing on to shaft 1 Examine the layshaft for wear and damage 2 Press bearings on to layshaft using MS 47 and WE E AA z um ope LL MAN Cm 57326 lt OVERHAUL 23 37 MANUALGEARBOX DEFENDER NOTE One bearing cage is twisted in SELECTORS manufacture The twist causes the gear to tilt on the shaft forcing the gear into 1 Examine selector rail and pins for wear and engagement Renew bearings if worn or if the damage gear jumps out of engagement 2 Examine first second selector fork for wear cracks and damage NOTE The the selector rail and fork is only supplied as complete assembly 3 Examine third fourth selector fork for wear cracks and damage 4 Examine fifth gear selector fork pads and pivot pins 5 Examine interlock spools for wear and damage ST3248M 2 Fitthe
5. and fit cover 10 ST3254M GEAR CHANGE HOUSING 1 With length of tube release the bias spring from adjusting screws o 2 Remove bias spring adjusting screws ST2182M 10 ovERHAUL 7 Clean and examine all components and renew where necessary 8 Assemble above parts in reverse order using multi purpose grease on gear lever A 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 trunnion 2 Remove circlip to release seating from trunnion 3 Remove fifth gear locknut and stud 4 Remove reverse gear plunger and shim S ed ST2183M 5 Remove fifth gear spool guide 6 Remove blanking plug 7 Drift out roll pin securing quadrant to shaft 8 With selector through hole 9 Remove selector shaft O ring ST3274M MANUAL GEARBOX 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
6. automatically aligned for third or fourth gear selection 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 A 4 Move lever to left and adjust right hand bolt to clearance 5 Tighten locknuts L 7 ENG 3 M A WF ST2198M pm Se 34 OVERHAUL 7775 BELL HOUSING FOUR CYLINDER ENGINE 1 Fit bellhousing locating over hollow dowels and secure with bolts NOTE Fit the 12x 45 mm bolts through dowels and 12x 30 mm bolts in remaining positions 2 Secure pivot post 3 Apply molybdenum disulphide grease to pivot post lever pads and pins 4 Assemble pads to lever and lever to bearing and fit assembly to pivot post 5 Fit staple to release assembly short leg to lever NOTE The staple is an aid to assembly JN only which may become dislodged or lost in service without detriment ST2202M 4 MANUAL GEARBOX BELL HOUSING V8 ENGINE 1 Fit bell housing locating on hollow dowels NOTE Fitthe 12x 45mm bolts through ZX dowels and 12x 30mm bolts in remaining positions 2 Apply molybdenum disulphide grease to pivot post release lever socket and push rod Not the bearing guide 3 Fit C washer t
7. housing m Ice e q OVERHAUL 1 37 mMANUALGEARBOX DEFENDER 4 Drive out quadrant roll pin 2 Using service tool 18G 705 and 18G 705 1A 5 Move selector shaft forward to remove withdraw the oil seal collar quadrant 18G 705 18G 705 1A 2 ST2180M 3 Remove the fifth gear extension housing Ml 4 Secure the centre plate to the gearcase with EXTENSION HOUSING two 8 x 35mm bolts 1 Remove snap ring retaining oil seal collar 0 SH NS Teu Noct 2 L S NT 7 je ST2316M N ST3272M D i 2 OVERHAUL 7775 MAINSHAFT AND AYSHAFT FIFTH GEARS __ 1 Remove mainshaft ring A GE pump drive shaft S See E clips from selector fork fifth gear selector spool ove selector fork bracket ST2294M 8G 1205 6 Locate flange holder too 1 d spacer to restrain 7 Fit manufactured tool A an layshaft fifth gear 8 De stake and remove fifth gear nut 18G1205 T2312M 9 Remove circlip retaining mai i a ner g mainshaft fifth gear 10 Fit special tool 18G 1400 illustrated Ne CAUTION ensure the puller feet locate the two cut outs in 18G 1400 1 and between the pins OVER 37 MANUALGEARBOX DEFENDER 11 Remove fifth gear synchromesh H ST2298M ST2296M 3 Invert gear case and locate studs in workstand E holes 12 Remove layshaft fifth gea
8. 4 Remove drain plug assembly Clean and renew 2 Inspect for damage and selector rail bore for filter and washers if necessary wear 5 Renew oil seal 3 Temporally fit reverse shaft gear and lever and 6 Renew Ferrobestos bush check clearance between slipper and lever does not exceed 0 20 mm 0 008 in WARNING This bush contains abestos Do not attempt to clean it see INTRODUCTION Information Poisonous LS substances 3 7 Fit new bush with drain holes towards bottom of casing CAUTION If drain holes not positioned correctly oil may build up behind oil seal and cause leak Extension case 1 Examine for damage to threads and machined faces 2 Remove oil pump cover inspect gears and housing and renew if required ST2336M 8 If extension housing is being renewed transfer grub screw to new housing Apply Loctite to threads di Q ST3273M 8 ST3218M OVERHAUL 9 37 MANUALGEARBOX DEFENDER 9 Fit oil seal to housing lip side leading using 18G 1422 Apply SAE 40 oil to lip ST2186M PTS 3 Drive out roll pin to remove bias spring 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 ST2334M 6 Remove gear selector housing from remote housing 10 Assemble gears to oil pump
9. ARING 32 LAYSHAFT BEARING ADJUSTMENT 32 GEAR LEVER AND REMOTE HOUSING ASSEMBLY 33 BELL HOUSING FOUR CYLINDER ENGINE 35 BELL HOUSING V8 ENGINE nennen nennen nnns 35 SPECIFICATIONS TORQUE DATA eege thiet o cutem GU aiii ten in lees 1 TORQUE VALUES 5 ct nec ott rer Eas no tennes ey Yann ee 1 SERVICE TOOLS SERVICE TOOLS ettet rere tente dece 1 37 MANUAL GEARBOX G3 CONTENTS Page LOCALLY MANUFACTURED TOOLS 3 GEARS AND SHAFTS 1 5 GEARBOX CASING oi EE 7 LT77S DISMANTLE Bell housing four cylinder engine 1 Remove transfer box drain oil and clean exterior 2 If fitted clutch release bearing clip 3 Remove clutch release assembly ST2179M 4 Remove one pivot post bolt slacken the other and move post aside 5 Remove six bolts and withdraw bell housing ST2177M Bell housing V8 engine 1 Remove clutch release bearing 2 Remove screw and spring clip and remove release lever 3 Remove clip from pivot post 4 Remove six bolts and bell housing MANUAL GEARBOX N 6 ST3284M GEAR SELECTOR HOUSING 1 Remove four bolts and remove main gearbox selector housing 2 Remove transfer box housing 3 Remove remaining bolts and remove remote
10. EARBOX 0 0 MAINSHAFT GEAR END FLOAT CHECKS Third gear end float Hold mainshaft in vice front end downwards 1 Fit needle roller to third gear 1 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 ST3235M ST3251M Second gear end float First gear bush end float 1 Fit needle roller and second gear 2 Fitthird gear bush 1 Invert mainshaft rear end uppermost 2 Fit inner and outer second gear baulk rings MU ST3250M 3 Check clearance between second gear and bush flange Not to exceed 0 20 0 008in 4 Remove above components een OVERHAUL 19 37 MANUALGEARBOX DEFENDER 3 Fit first second synchromesh hub fork groove 8 Fitfirst gear bush 9 Fitdummy bearing uppermost 4 Fit circlip 10 Fit circlip 11 Check clearance between dummy bearing and bush Not to exceed 0 75mm 0 003in 12 Remove circlip dummy bearing and bush ST3231M First second synchromesh assembly ST3253M Selective first gear bush P 2 Part number Thickness FTC2005 30 905 30 955 FTC2006 30 955131 005 FTC2007 31 005131 055 FTC2008 31 055 31 105 FTC2009 31 105 31 155 Check first gear to bush end float 1
11. Fit roller bearing and bush to first gear 5 3257 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 5 Fit first gear inner and outer baulk ring 6 Fit cone that the gear is suspended and does not 7 Fit spacer rest on the flat surface 20 OVERHAUL 1775 MANUAL GEARBOX 3 Place straight edge across gear and check clearance between gear and straight edge Not to exceed 0 20mm 0 008in ST3255M ASSEMBLING MAINSHAFT 4 Fitthe taper bearing to mainshaft using MS 47 collets 18G 47 BA and adaptor 18G 47 1 With the first second synchromesh hub and spacer in position assemble the rear end of the shaft Fit the roller bearing and bush to first gear Fit first gear to mainshaft 573229 18G47BAX 18G47BA First gear assembly OVERHAUL 21 37 MANUAL GEARBOX DEFENDER CAUTION Ensure that the slots in the 7 Position mainshaft in vice rear end downwards baulk ring align with the synchromesh and fit second gear needle roller and second slippers while pressing on the bearing gear 8 Fit third gear bush 5 Invert mainshaft and press assembly back 9 Fitthird gear needle rollers against circlip 10 Fit third gear 11 Fitthird gear baulk ring MS 47 ze RF 0015015 m kr 10 Wail a i Ya 2 ST3264M
12. TOOLS DEFENDER 18G 1431 18G 1431 Mainshaft rear oil seal replacer EI 9 SCH 1861205 18G 1205 Flange holder no LT77S MANUAL GEARBOX LOCALLY MANUFACTURED TOOLS Tool C Mild steel dummy centre bearing for the Mull ETERNI MEM selection of first gear bush In addition to the special service tools the following tools can be locally made to assist the dismantling and assembly of the gearbox The following overhaul procedure is based upon the assumption that these tools available 530mm Tool A Dual purpose tool Reverse shaft retainer to e 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 38 3mm 0 005 0 000 0 000 ST2154M 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 BS D 4 100mm I net i M i ST2156M 20mm 25mm Tool Four pilot studs with an 8mm thread for locating in the four counter sunk blind holes in the workstand 12mm B ST1118M ST 2155M SERVICE TOOLS 3 37 MANUALGEARBOX DEFENDER 1 Tool E Works
13. ar of the assembly with the gear teeth single tag locating in a slot in the inner member 13 3 N i epa 5 3247 5 3276 16 OVERHAUL 1775 MANUAL GEARBOX CHECKING BAULK RING CLEARANCES Third gear 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 ST3260M Fourth gear ST3226M Fifth gear ST3259M ST3261M OVERHAUL 17 37 MANUALGEARBOX INPUT SHAFT 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 18G284AAH 18G284 ST3278M 4 Using 18G 47BA and MS 47 remove taper bearing NOTE ensure that the bearing is ZEN supported by the lip inside 18G 47 BA ST3279M 5 Support the shaft under MS 47 and press in a new track DEFENDER 6 Using Press MS 47 Collets 18G 478 and adaptor 18G 47 BAX fit a new taper bearing gr te ST3268M 18G 47BA MAINSHAFT Examine bearing journals for wear and scores Check condition of circlip grooves Examine splines for wear and damage Use an air line to check that the main oil feed from the pump is clear and feed to spigot bearing Check oil feed holes to roller bearings are clear RON a 5 ST3241M 18 OVERHAUL 17775 MANUAL G
14. 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 ST2447M 4 Examine idler shaft for wear scores and oitting LT77S MANUAL GEARBOX Assembling selectors ASSEMBLING GEARBOX SHAFTS TO CENTRE PLATE 7 Rest first second fork and shaft assembly on bench and locate pin in jaw of fork Fitting gears to centre plate 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 ST2488M 9 Slide spool and fork towards first second selector until slot spool locates over pin keeping the spool engaged in third fourth fork jaw 2 Check both synchromesh units in neutral and fit selector shaft assembly 3 Fit mainshaft and selectors to centre plate and align pin with slot in plate ST2487M CA ei I ER ST2495M pe IL OVERHAUL 25 37 MANUALGEARBOX DEFENDER 4 Fit layshaft While lifting mainshaft to clear 10 Secure reverse shaft with manufactured tool layshaft rear bearing 5 Turn selector shaft and interlock spool to allow 11 reverse gear thrust washer to shaft reverse lever to engage spool flange 12 Fit fourth gear baulk ring 6 Fit
15. ess mm 1 51 1 57 163 1 69 1 75 1 81 1 87 1 93 1 99 2 05 2 11 2 17 2 23 2 29 2 35 2 41 2 47 2 53 2 59 2 65 2 67 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 shim that will provide clearance equal to the thickness of the gasket that was selected and measured when calculating the adjustment of the input and mainshaft bearing ST2503M EN sp r LT77S MANUAL GEARBOX NOTE This will ensure zero layshaft GEAR LEVER AND REMOTE HOUSING bearing end float and not more than ASSEMBLY 0 025mm 0 001in pre load once the cover and gasket are fitted and bolts correctly 1 Fit quadrant to selector shaft with new roll pin torqued NOTE Push shaft forward fit quadrant 3 Remove cover and selected washer and fit new ZN SO ledge is to the left viewing box from rear Return shaft to neutral position oil seal lip towards gearcase 4 Fit mainshaft and layshaft selected washers and gasket ST2191M SCH 2 With a new gasket fit remote housing locating over dowels 5 Wrap protective tape round input shaft splines 6 Apply Hylomar PL 32 to bolt threads and secure NOTE Ensure rollers locate in quadrant cover fork Layshaft selective washers 3 Fittransfer gear change housing Par
16. eve the non metallic bushes Remove circlip to release ball and seat and withdraw gear lever Remove screws from end cover to withdraw cover and cross shaft Remove selector fork Remove detent spring and plate Clean and examine ail parts and renew where necessary MANUAL GEARBOX NOTE Assemble the housing using multi purpose grease on all moving parts Fit internal and external rings to fork assembly Fit detent spring Fit rings to end cover and fit to short end of cross shaft Insert shaft into fork and secure end cover with screws Fit Nylon seat groove downwards to gear lever Fit gear lever and seat to cross shaft and secure with circlip Fit bushes to gear lever and secure with clevis pin and split pin OVERHAUL 13 37 MANUALGEARBOX DEFENDER 15 E 16 ST2185M 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 mettalic bushes 5 Gasket 15 Counter sunk screws 6 Split pin 16 End cover 7 Clivis pin 17 Detent spring and plate 8 Circlip retaining Nylon seat 18 Selector fork 9 Gear lever ball 19 O rings 10 Nylon seat 14 OVERHAUL SYNCHROMESH ASSEMBLIES Third fourth and fifth gear synchromesh NOTE the above assemblies are the same except that fifth gear synchromesh has retainer pla
17. haft splines with smooth tape 18G1431 3 Fit ring to mainshaft groove ST 3221M ST2512M 4 Rt O ring collar to mainshaft using 18G 1431 OVERHAUL 31 37 MANUALGEARBOX INPUT MAINSHAFT BEARING ADJUSTMENT 1 A Turn gearbox over with input shaft uppermost Remove layshaft support plate NOTE Correct shimming of the input shaft bearing is vital to ensure that the mainshaft assembly has the design intended end float and the bearings are not pre loaded 2 3 573269 5 Measure the thickness of new front cover gasket Place the original shim on mainshaft bearing and finger tighten the bolts Measure the clearance between front cover and gearcase with two feeler gauges 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 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 32 Remove front cover and keep gasket and selective washer together OVERHAUL DEFENDER Mainshaft selective washers Part number FRC 4327 FRC 4329 FRC 4331 FRC 4333 FRC 4335 FRC 4337 FRC 4339 FRC 4341 FRC 4343 FRC 4345 FRC 4347 FRC 4349 FRC 4351 FRC 4353 FRC 4355 FRC 4357 FRC 4359 FRC 4361 FRC 4363 FRC 4365 FRC 4367 FRC 4369 Thickn
18. im Taper bearing Layshaft fourth gear Layshaft third gear Layshaft second gear Layshaft reverse gear Layshaft first gear Taper bearing Layshaft fifth gear Layshaft fifth gear retaining stake nut Circlips retaining first gear and first second gear synchromesh MANUAL GEARBOX Snap ring retaining second gear cone and spacer Spacer Snap ring Reverse idler gear Thrust washer Snap ring Fifth gear spool SERVICE TOOLS 5 37 MANUALGEARBOX DEFENDER a ZS MT ST3281 M 6 SERVICE TOOLS LT77S GEARBOX CASING Front cover Front cover oil seal Front cover gasket Oil drain plug and washer Oil level plug Gearbox main casing Spool retainer Gasket Inboard detent ball and spring Reverse lever and slipper A Reverse lever pivot post Centre plate ST3287M Locating dowels centre plate to maincase MANUAL GEARBOX Selector plug detent ball and spring Gasket Fifth gear selector bracket Fifth gear selector fork Reverse gear shaft Oil pick up pipe Oil pump drive shaft Oil pump gears and cover Fifth gear extension housing Fifth gear extension housing drain plug and filter Ferrobestos bush Oil seal SERVICE TOOLS 7
19. ivot post nut Clutch housing to gearbox bolts Plug detent spring and ball drain plug Oil filter plug Oil filler level plug Breather Fifth gear layshaft stake nut Bottom cover to clutch housing MANUAL GEARBOX 0 725 mm 45 to 55 kg 8 2 to 10 kgf 0 38 mm 0 20 mm 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 14 16 204 231 7 10 SPECIFICATIONS TORQUE 1 MANUAL GEARBOX LT77S SERVICE TOOLS 18G 1400 NOTE Where the use of special tools is ZA specified only these tools should be used to avoid the possibility of personal injury and or damage to components 18G 705 Remover synchromesh hub and gear cluster 8G 1400 1 Adaptor mainshaft fifth gear 18G 1400 18G 7400 1 18G 705 Puller bearing remover 18G 705 1A 52 D 8G 705 1A Adaptor for mainshaft seal track and layshaft fifth gear 18G 705 7 MS47 we 15 47 Hand press 18G 47BA 8G 705 7 Adaptor for layshaft bearings 8G 47BA Adaptor input shaft bearing SERVIGE TOOLS 1 37 MANUAL GEARBOX 18G 47BAX N 18G 47BAX Conversion kit 18G 284 MS 284 18G 284 Impulse extractor 18G284AAH 8G 284AAH Adaptor for input shaft pilot bearing track 18G 1422 8G 1422 Mainshaft rear oil seal replacer 2 SERVICE
20. o pivot post 4 Fit spring clip to lever and fit lever to pivot post NOTE Position spring clip behind C washer and tighten screw 5 Fit bearing and retain with plastic staple ST3285M ST3286M OVERHAUL 35 LT77S DATA Reverse lever and slipper pad clearance Reverse gear plunger operating load Synchromesh assemblies push through load Clearance between baulk rings and gears Fifth gear end float 5 eerie tn Third gear end float Second gear end float First gear bush end float First gear end float Fifth gear synchromesh end TORQUE VALUES NOTE Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque 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 p
21. r using special tools 4 Remove selector shaft spool retainer 18G 705 18G 705 14 N 4 7 06 186705 UT 18G705 1A ST2300M 3 Main gear case 1 Secure reverse shaft retainer manufactured tool A to centre plate 2 Fit studs manufactured tool B to gear case 4 OVERHAUL 117775 MANUAL GEARBOX 0 0 REVERSE SHAFT LAYSHAFT AND MAINSHAFT 5 Remove front cover and gasket 6 Retrieve selective washers 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 d 7 Remove bolts and lift off gear case 8 Secure centre plate with nut and bolt ST3237M ST2301M N I OVERHAUL 5 37 MANUALGEARBOX DEFENDER 5 Remove input shaft and fourth gear baulk ring 6 Remove layshaft by tilting as illustrated and lifting mainshaft ST3245M 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 11 Collect inboard detent ball and spring from centre plate ST3240M 6 OVERHAUL LT77S MANUAL GEARBOX 0 0 12 Using extractor tool 18G 705 and collets 18G 705 7 withdraw layshaft bearings 18G 705 7 i vo
22. reverse lever to pivot post and secure with 13 Lubricate spigot bearing and fit input shaft pin and circlip 14 Remove centre plate workstand bolt and fit 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 eo 004 mrs a 2 mJ ST2492M d 26 OVERHAUL FITTING GEARBOX CASING 1 Turn selector shaft and spool to neutral position 2 Fit out board detent ball and spring and secure ST2515M CAUTION Do not use force to fit retainer 2 Provided the spool has not been disturbed the retainer will slide into ST2494M position If not remove the gear case and reposition spool or shaft 3 Fit guide studs to casing and check oil scoop IS 7 Remove detent plug apply Loctite 290 or correctly fitted Hylomar PL 32 to thread refit and stake 4 Without using force fit gearcase 8 layshaft and input shaft bearing tracks NOTE Ensure that the centre plate dowels and selector shaft are properly located 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 ST2496M OVERHAUL 27 MANUALGEARBOX 37 FITTING FIFTH GEAR CAUTION Since the fifth gear is a tight N fit on the layshaft the force when pressing the gear mus
23. t not be transfered 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 1 Secure the plate with two 8x25mm bolts Insert disc between plate 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 186 1422 28 OVERHAUL DEFENDER 4 Fit a new stake nut but do not tighten 5 Fit fifth gear assembly to mainshaft e GEES PA 444 P Am z ST2497M LT77S 6 Press fifth gear synchromesh assembly to mainshaft using 18G 1431 CAUTION Before pressing the assembly fully home ensure that the slipper pads locate in the baulk ring slots lt gt OG 1861431 ST2498M 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 0002 to 0 002in and to achieve this the following selective washers are available MANUAL GEARBOX Part number Thickness 5284 5 10 5286 5 16 5288 5 22 5290 5 58 5292 5 34 5294 5 40 5296 5 46 5298 5 52 5300 5 58 5302 5 64 Fitthe thinnest washer secure with circlip
24. t number Thickness mm Reverse gear plunger adjustment FTC 0262 1 36 1 Fit plunger with original shims and tighten bolts FTC 0264 1 42 2 Slacken locknut turn adjuster screw so that FTC 0266 1 48 dimension A is approximately 12 mm 0 50 FTC 0268 1 54 in Tighten locknut FTC 0270 1 60 FTC 0272 1 66 FTC 0274 1 72 Ul 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 ST3223M OVERHAUL 33 MANUALGEARBOX 37 NOTE If necessary final adjustment can be made in vehicle To increase pull over load turn screw clockwise or anti clockwise to reduce load Fifth gear stop screw adjustment 1 Adjust screw to protrude from housing the distance across corners of locknut NOTE This is only an approximate setting which will limit travel of selector yoke but will allow fifth gear to be selected ST3225M 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 ST2197M DEFENDER Bias spring 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 the gear change mechanism is
25. tand for securely locating the gearbox The four counter sunk blind holes marked B should during overhaul Manufacture from 30mm x 30mm also be made with a 10mm drill but must not be angle iron The single hole marked should be drilled through the material drilled through the material with a 10mm drill e 134mm a 115mm 228mm ST2153M s 4 SERVICE TOOLS GEARS AND SHAFTS Third fourth selector fork Interlock spool First second fork and selector rail assembly First second synchromesh First gear synchromesh outer baulk ring First gear synchromesh inner baulk ring Cone Thrust washer First gear Needle roller bearings First gear selective bush Centre taper roller bearing Circlip Thrust washer Fifth gear Fifth gear baulk ring Fifth gear synchromesh Fifth gear synchromesh back plate Fifth gear synchromesh selective washer Circlip O ring Oil seal collar Snap ring Fourth gear baulk ring Pilot taper bearing Spacer Third fourth synchromesh Third gear baulk ring Third gear Third gear bush Second gear Thrust washer Cone Second gear synchromesh inner baulk ring Second gear synchromesh outer baulk ring Mainshaft Input shaft bearing track and selective washer Input shaft Input shaft taper bearing Fourth gear Selective sh
26. te 1 Mark relationship of inner and outer members 2 Remove wire clip from both sides of assembly ST3243M 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 MANUAL GEARBOX ST2803M 7 Examine the dog teeth on all gears for wear and damage NOTE example A shows tooth in good condition Example B shows the rounded corners of a worn tooth ST2449M OVERHAUL 15 37 mANUALGEARBOX DEFENDER 12 Fitthe slippers and secure with spring each First second synchromesh side of the synchromesh 8 Repeat instructions 1 to 6 for third fourth synchromesh NOTE The hooked end of each spring 9 Examine step in each of outer splines must locate in the same slipper with the 10 Check that the step on both sides of the free ends running in opposite directions and resting against the remaining slippers internal splines are sharp not rounded NOTE this applies only to splines on SC selector groove side of member ST2467M 13 Assemble third fourth and fifth gear synchromesh components as in instruction 12 ST3244M 11 Ht inner member to outer so that the wide NOTE The back plate for fifth gear is splines of inner member are under the spur fitted to the re
27. 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 bucket plug with Hylomar PL 32 22 Fit gear selector housing to remote housing 44 WE H a P ST2188M Gear selector housing Gasket Roll pin Bias spring Gear lever retaining screw and washer Selector housing screws Gear lever Nylon pad and spring Gear lever extension Remote housing Gasket Fifth gear spool guide _ Fifth gear stop screw and lock nut 14 15 16 17 18 19 20 21 22 23 24 25 DEFENDER Reverse gear plunger Gear lever seating Trunnion Circlip Trunnion retaining screw ring Selector shaft Quadrant Roll pin Rollers Pin Bianking 1775 Reverse gear plunger assembly RON A Remove plug spring and ball Remove circlip to release plunger and spring Clean and examine components Assemble plunger and spring with multi purpose grease and secure with circlip Lubricate and fit detent ball and spring with light oil Apply Loctite 290 to plug threads and fit Check that plunger returns when depressed ST2201M Transfer gear housing 1 RO Remove the four screws and remove gaiter assembly Disconnect the gear lever from selector fork Retri
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