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DEFENDER
LT77S GEARBOX
WORKSHOP MANUAL SUPPLEMENT
Publication Number SLR 621 EN WS 2
Published by the Land Rover
Technical Publications Department of Lode Lane
Solihull
1,
West Midlands, 892 8NW
England
@ Copyright Land Rover 1991
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37 . MANUAL GEARBOX ..... ...... ..... ..... .... ..... .*. . ....)I .... CONTENTS Page OVERHAUL DISMANTLE ..................................................................................................... 1 GEAR SELECTOR HOUSING .......................................................................... 1 EXTENSION HOUSING .................................................................................... 2 MAINSHAFT AND LAYSHAFT FIFTH GEARS ...................................
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~~ ~ 37 - MANUAL GEARBOX CONTENTS Page LOCALLY MANUFACTURED TOOLS .............................................................. 3 GEARS AND SHAFTS ..................................................................................... 5 GEARBOX CASING ......................................................................................... 7
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LT77S MANUAL GEARBOX - I. 2 I. r 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. 4. Remove one pivot post bolt, slacken the other and move post aside. GEAR SELECTOR HOUSING 5. Remove six bolts and withdraw bell housing. 1. Remove four bolts and remove main gearbox selector housing. 2. Remove transfer box housing. 3. Remove remaining bolts and remove r
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I 37 MANUALGEARBOX 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 n /U 5 ST2180M 3. Remove the fifth gear extension housing. 4. Secure the centre plate to the gearcase with EXTENSION HOUSING . two 8 x 35" bolts. 1. Remove snap ring retaining oil seal collar. ST2316M 2 I OVERHAUL
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LT77S MANUAL GEARBOX '.. ~$ ':. .: I.. r. ~. ., 9. Remove circlip retaining mainshaft fifth gear synchromesh. MAINSHAFT AND LAYSHAFT FIFTH GEARS 10. Fit special tool 18G 1400-1 and 18G 1400 as illustrated. 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. .. .. .:
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137 MANUALGEARBOX DEFENDER 11. Remove fifth gear synchromesh. I1 -. i ST2296M 3. Invert gear case and locate studs in workstand - holes. 12. Remove layshaft fifth gear using special tools 4. Remove selector shaft spool retainer. 18G 705 and 18G 705-1A. 18G705-1A Main gear case. 1. Secure reverse shaft retainer, manufactured tool "A"; to centre plate. 2. Fit studs, manufactured tool"B" to gear case. 4 1 OVERHAUL
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LT77S MANUAL GEARBOX 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. Remove reverse lever pin with "E" clip 3. attached. Remove lever and slipper pad. 4. 7. Remove bolts and lift-off gear case. 8. Secure centre plate with nut and bolt. ST23OlM Yt II I
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I 37 MANUALGEARBOX DEFENDER 5. Remove input shaft and fourth gear baulk ring. 6. Remove layshaft by tilting, as illustrated and lifting mainshaft. 5 ST U I ST3245 M 7. Unscrew plug and remove spring and outboard 11. Collect inboard detent ball and spring from detent ball. centre plate. 8. Align fifth gear selector pin with centre plate slot. 9. Remove mainshaft, gears, selectors and forks. 10. Remove selector fork assembly from gears.
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Ll77S MANUAL GEARBOX .. c:". .:: , , . , I I . . , ,.. . ..::.:, , ... ... 1 .. 12. Using extractor tool 18G 705 and collets 18G 705-7, withdraw layshaft bearings. \ ST3246M, \ . -. DISMANTLE MAINSHAFT 1. Remove circlip retaining first gear assembly. 4. With MS 47 press first gear assembly from mainshaft. r -i ST 4 R 2. Remove taper bearing, bush, needle bearing, first gear spacer, cone, inner and outer baulk I/ A rings. 3. Remove circlip to release first and second gear
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137 MANUALGEARBOX DEFENDER (3 5. Remove first and second synchromesh baulk L.. 7 GEARBOX CASINGS AND OIL PUMP rings. 6. Using MS 47 and support bars under second Degrease and clean all components and discard gear, press off pilot bearing, third, fourth gaskets and seals. synchromesh second and third gear assembly. Gearbox casing 1. Remove mainshaft and layshaft bearing tracks. 2. Remove plastic scoop from inside the casing. ST3326M 64 i 3. Inspect case for damage, cracks and strip
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LT77S MANUAL GEARBOX 3. Check oil pick up pipe for obstruction but do Centre plate not remove. 1. Remove bearing tracks. 4. Remove drain plug assembly. Clean and renew 2. Inspect for damage and selector rail bore for filter and washers if necessary. 5. Renew oil seal. wear. 6. Renew Ferrobestos bush. 3. Temporally fit reverse shaft gear and lever and check clearance between slipper and lever does not exceed 0,20 mm (0.008 in). WARNING: This bush contains abestos. A Do not attempt to
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I 37 MANUALGEARBOX DEFENDER 9. Fit oil seal to housing, lip side leading, using 18G 1422. Apply SAE 40 oil to lip. ST2186M 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 A pad while removing the lever to prevent it causing personal injury. 6. Remove gear selector housing from remote housing. 10. Assemble gears to oil pump and fit c
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LT77S MANUAL GEARBOX , "' 7. Clean and examine all components and renew 10. Remove circlip to release rollers and pin from where necessary. quadrant. 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
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DEFENDER 1 - I 37 MANUAL GEARBOX (, . -_ GEAR SELECTOR HOUSING 1.: t I 0,: i/' 14. Reverse gear plunger 15. Gear lever Seating 1. Gear selector housing 16. Trunnion 2. Gasket 3. Roll pin 19. '0' ring 20. Selector shaft 21. Quadrant 22. Roll pin 23. Rollers i
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LT77S MANUAL GEARBOX Reverse gear plunger assembly. NOTE: Assemble the housing using A mutti-purpose grease on all moving parts. 1. Remove plug spring and ball. 2. Remove circlip to release plunger and spring. 9. Fit internal and external "0" rings to fork 3. Clean and examine components. assembly. 4. Assemble plunger and spring with multi-purpose 10. Fit detent spring. grease and secure with circlip. 11. Fit "0" rings to end cover and fit to short end 5. Lubricate and fit detent ball an
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137 MANUALGEARBOX DEFENDER - 12 15 I 17 ST 2185 M 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. "0" rings. 10. Nylon seat.
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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. ST2803M 7. Examine the dog teeth on all gears for wear and damage. NOTE: example"A shows a tooth in a good condition. Example"6" shows the rounded corners of a worn tooth. 3. Remove slippers and separate th
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137 MANUALGEARBOX DEFENDER r; First-second synchromesh 12. Fit the slippers and secure with a spring each 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 internal splines are sharp not rounded. and resting against the remaining slippers. NOTE:
