Land Rover LT77S User Manual
.-
-... .
..1.
..~.
.
,.
I.
._
,
..:.::
. . ..
425DDEFENDER
.
90.110
130
1,
WORKSHOP MANUAL SUPPLEMENT
Publication Number SLR 621 EN WS 2
Published by the
Technical Publications Department
@
Copyright Land Rover 1991
of
DEFENDER
LT77S GEARBOX
Land Rover
Lode Lane
Solihull
West Midlands, 892 8NW
England
.....
......
.....
.....
....
.....
.
....)I
....
37
.
MANUAL
.*.
GEARBOX
CONTENTS
Page
OVERHAUL
DISMANTLE
GEAR SELECTOR HOUSING
EXTENSION HOUSING
MAINSHAFT AND LAYSHAFT FIFTH GEARS
REVERSE SHAFT, LAYSHAFT AND MAINSHAFT
DISMANTLE MAINSHAFT
GEARBOX CASINGS AND OIL PUMP
GEAR CHANGE HOUSING
GEAR SELECTOR HOUSING
SYNCHROMESH ASSEMBLIES
CHECKING BAULK RING CLEARANCES
INPUT SHAFT
MAINSHAFT
MAINSHAFT GEAR END FLOAT CHECKS
ASSEMBLING MAINSHAFT
LAYSHAFT
REVERSE GEAR AND SHAFT
SELECTORS
ASSEMBLING GEARBOX SHAFTS TO CENTRE PLATE
FITTING GEARBOX CASING
FITTING FIFTH GEAR
FIFTH GEAR SELECTOR FORK ASSEMBLY
EXTENSION CASE
INPUT
-
MAINSHAFT BEARING ADJUSTMENT
LAYSHAFT BEARING ADJUSTMENT
GEAR LEVER AND REMOTE HOUSING ASSEMBLY
BELL HOUSING
BELL HOUSING
.....................................................................................................
..........................................................................
....................................................................................
..................................................
...........................................
................................................................................
.............................................................
............................................................................
........................................................................
....................................................................
......................................................
................................................................................................
...................................................................................................
....................................................
...........................................................................
.....................................................................................................
......................................................................
..................................................................................................
.........................................................................
....................................................................................
................................................
........................................................................................
..............................................
............................................................
...................................
-
FOUR CYLINDER ENGINE
-
V8 ENGINE
.......................................................................
...............................................
..............................
1
1
2
3
5
7
8
10
12
15
17
18
18
19
21
23
23
24
25
27
28
30
31
32
32
33
35
35
SPECIFICATIONS. TORQUE
DATA
TORQUE VALUES
SERVICE TOOLS
SERVICE TOOLS
...............................................................................................................
...........................................................................................
.............................................................................................
1
1
1
37
~
-
MANUAL
CONTENTS
~~
GEARBOX
Page
LOCALLY MANUFACTURED TOOLS
GEARS
GEARBOX
AND SHAFTS
CASING
.........................................................................................
.....................................................................................
..............................................................
3
5
7
LT77S
-
I.
2
I.
r
DISMANTLE
MANUAL
GEARBOX
Bell housing
1.
Remove transfer box, drain
-
four cylinder engine
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.
5.
Remove
six
bolts and withdraw bell housing.
GEAR
SELECTOR
1.
Remove four bolts and remove main gearbox
HOUSING
selector housing.
2.
Remove transfer box housing.
3.
Remove remaining bolts and remove remote
housing.
Bell housing
1.
Remove clutch release bearing.
2.
Remove screw and spring clip and remove
-
V8
engine
release lever.
3.
Remove
4.
Remove six bolts and bell housing.
"C"
clip from pivot post.
I
37
4.
Drive out quadrant
5.
Move selector shaft forward to remove
quadrant.
MANUALGEARBOX
roll
pin.
2.
Using service
withdraw the oil seal collar.
tool
18G
&-
705
DEFENDER
and
18G 705
-
1A
n
5
ST2180M
EXTENSION
1.
Remove snap ring retaining oil seal collar.
HOUSING
.
18G 705
/U
3.
Remove the fifth gear extension housing.
4.
Secure the centre plate
two
8 x 35" bolts.
to
the gearcase with
ST2316M
2
I
OVERHAUL
'..
':.
.:
r.
.,
~$
.:
I..
~.
LT77S
MAINSHAFT AND LAYSHAFT FIFTH GEARS
1.
Remove mainshaft
2.
Remove
3.
Remove
4.
Remove fifth gear selector
5.
Remove selector fork bracket.
oil
pump drive shaft.
"E"
"0"
ring.
clips from selector fork.
Spool.
MANUAL
9.
Remove circlip retaining mainshaft fifth gear
GEARBOX
synchromesh.
10.
Fit special tool
18G
1400-1
and
18G
illustrated.
1400
as
..
..
137
11.
Remove fifth gear synchromesh.
ST2296M
12.
Remove layshaft fifth gear using special tools
18G
MANUALGEARBOX
705
and 18G
705-1A.
DEFENDER
I1
3.
Invert gear case and locate studs in workstand
holes.
4.
Remove selector shaft spool retainer.
i
-.
-
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
LT77S
MANUAL
GEARBOX
5.
Remove front cover and gasket.
6.
Retrieve selective washers.
7.
Remove
8.
Secure centre plate with nut and
bolts
and lift-off gear case.
bolt.
REVERSE
1.
2.
3.
4.
SHAFT,
Remove retainer (tool
Remove
spacer.
Remove reverse lever pin with
attached.
Remove lever and slipper pad.
LAYSHAFT
thrust
washer, reverse gear and
AND MAINSHAFT
"A"
)
and reverse shaft.
"E"
clip
ST23OlM
Yt
II
I
I
37
5.
Remove input shaft and fourth gear baulk ring.
6.
Remove layshaft by tilting, as illustrated and
lifting mainshaft.
MANUALGEARBOX
DEFENDER
5
ST
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.
ST3245
M
11.
Collect inboard detent ball and spring from
centre plate.
I
U
Ll77S
c:".
..
.::
,
, . ,
I
I
. .
,
,..
.
..::.:,
,
...
...
1
..
12.
Using extractor tool
705-7,
withdraw layshaft bearings.
18G
705
and collets
18G
MANUAL
GEARBOX
-.
ST3246M,
DISMANTLE
\
1.
Remove circlip retaining first gear assembly.
\
.
MAINSHAFT
4.
With
mainshaft.
MS
47
press
first
gear assembly from
r
-i
ST
2.
Remove taper bearing, bush, needle bearing,
first gear spacer, cone, inner and outer baulk
rings.
3.
Remove circlip
synchromesh assembly.
to
release
first
and second gear
4
R
I/
A
137
5.
Remove first and second synchromesh baulk
rings.
6.
Using
gear, press
synchromesh second and third gear assembly.
MANUALGEARBOX
MS
47 and support bars under second
off
pilot bearing, third, fourth
DEFENDER
GEARBOX CASINGS AND
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.
OIL
PUMP
(3
L..
7
ST3326M
64
7. Remove washer, third, fourth synchromesh,
8.
i
third gear baulk ring, split needle rollers, bush,
needle bearing and second gear.
Remove snap ring, spacer, second gear cone
and circlip.
3.
Inspect case for damage, cracks and stripped
threads.
4. Fit a new scoop with scoop side towards top of
casing.
Front cover
1.
Remove oil seal from cover.
seal at this stage
Do
not fit a new
ST3234M
LT77S MANUAL
3.
Centre plate
1.
Remove bearing tracks.
2.
Inspect for damage and selector rail bore for
wear.
3.
Temporally fit reverse shaft gear and lever and
check clearance between slipper and lever
does not exceed
0,20
mm
(0.008
in).
Check oil pick up pipe for obstruction but do
not remove.
4.
Remove drain plug assembly. Clean and renew
filter and washers if necessary.
5.
Renew oil seal.
6.
Renew Ferrobestos bush.
WARNING: This bush contains abestos.
A
substances.
A
Do
not attempt
INTRODUCTION,
7.
Fit
new bush with drain holes towards
casing.
CAUTION: If drain holes are not
positioned correctly oil may build up
behind oil seal and cause a leak.
GEARBOX
to
clean it. see
Information, Poisonous
bottom
of
ST3238M
Extension case
1.
Examine for damage
faces.
2.
Remove oil pump cover, inspect gears and
housing and renew if required.
to
threads and machined
8.
If extension housing is being renewed transfer
grub screw
threads.
to
new housing. Apply Loctite to
ST3218M
I
37
9.
Fit oil seal to housing, lip side leading, using
18G
MANUALGEARBOX
1422.
Apply
SAE
40
oil
to
lip.
DEFENDER
ST2186M
3.
Drive-out
4.
Remove gear lever extension from lower gear
lever.
5.
Remove bolt and special washer to remove
lower gear lever.
roll
pin
to
remove bias spring.
10.
Assemble gears to oil pump and fit cover.
WARNING: Hold
A
pad while removing the lever to prevent
causing personal injury.
6.
Remove gear selector housing from remote
housing.
the nylon spring loaded
it
ST3254M
GEAR CHANGE
1.
With a length of tube, release the bias spring
from adjusting screws.
2.
Remove bias spring adjusting screws.
10
I
OVERHAUL
HOUSING
LT77S
,
"'
7.
Clean and examine all components and renew
where necessary.
8.
Assemble above parts
multi
-
purpose grease
In
reverse order using
on
gear lever.
MANUAL
10.
Remove circlip to release rollers and pin from
quadrant.
GEARBOX
NOTE:
properly located and that the lever
fitted
Ensure spring loaded pad
to
the housing with the pad on the
is
is
opposite side to the bias spring. Leave bias
spring adjusting screws slack until assembly
of
gearbox.
Remote gear
1.
Release socket headed screw
trunnion.
2.
Remove circlip to release seating from trunnion.
3.
1
.:
',
Remove fifth gear locknut and stud.
4.
Remove reverse gear plunger and shim.
I
/
lever
4,
housing.
to
remove
ST3274M
U
fg$y
ST2183M
5.
Remove fifth gear spool guide.
6.
Remove blanking plug.
7.
Drift-out roll pin securing quadrant
8.
With selector
9. Remove selector shaft
thr~ugh
hole.
"0"
ring.
to
shaft.
11.
Clean and examine all components and renew
where necessary.
12.
Assemble housing by first fitting
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
17.
Fit seating
18.
Fit trunnion
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
22.
Fit gear selector housing to remote housing.
290
to
reverse switch threads.
to
trunnion
to
shaft and apply Loctite to
and
"0"
ring
secure with circlip.
PL
32.
to
Loading...