Land Rover Defender 90 110 Workshop Book 3 Rover

Section - .- .  L .I. y;. Number I.. 
37 
CONTENTS 
LT230R TRANSFER GEARBOX 
Page 
* 
LT77 FIVE SPEED  GEARBOX 
J 
37 LT95 FOUR SPEED  GEARBOX  AND TRANSFER BOX 
37 
- Overhaul 
Renew  front output  shaft 
oil seals 1 can be 
LTWLT230T MAIN GEARBOX  AND TRANSFER  BOX 
20 
18 
51 REAR DIFFERENTIAL - NINETY HEAVY DUTY 
- Remove  61 
- Overhaul LT85 gearbox 62 
37 I LT230T TRANSFER GEARBOX 
L 
51 
- Remove from LT85 gearbox 
- Overhaul 
REAR DIFFERENTIAL - NINETY 
147 I PROPELLER SHAFTS 
86 
91 
-Overhaul...

INTRODUCTION 
This Workshop  Manual  covers  the Land  Rover  Ninety  and  One Ten range of vehicles.  It is primarily  designed  to 
assist  skilled technicians 
in the efficient  repair and maintenance  of Land Rover  vehicles. 
Using  the  appropriate  service  tools and  carrying out the procedures  as  detailed will enable  the operations 
to be 
completed  within the time  stated  in 
thc Repair Operation  Times. 
The  Manual  has been  produced 
in separate  books;  this allows  the information...

Always have a fire  extinguisher containing  FOAM CO2 GAS, or POWDER  close at hand when handling or draining 
fuel, 
or when  dismantling  fuel systems  and in areas where fuel  containers  are stored. 
Always  disconnect  the vehicle  battery BEFORE  carrying out dismantling 
or draining work on a fuel  system. 
Whenever 
petroVgasoline is  being  handled, draincd or stored,  or when fuel systems  are being  dismantled  all forms  of 
ignition must  be 
extinguishcd or  removed, any head-lamps  used...

. Special Service Tools 
The use of approvcd special scrvice tools is important. Thcy are essential if scrvicc opcrations arc 
to  be 
carricd out  cfficicntly,  and safely. The amount of timc which thcy save can be considcrable. 
Every  special tool is designcd with the closc co-operation of Land Rover Ltd.,  and no tool  is put 
into  production  which has 
not been tested  and  approvcd  by us.  New  tools are only  introduced 
wherc an operation cannot  be satisfactorily carried out using cxisting...

LT77 FIVE SPEED GEARBOX 1371 
-.x,,

1371 LT77 FIVE SPEED GEARBOX 
25. Remove  the three  nuts and bolts  securing  the transfer 
box  L.H.  and R.H.  mounting  brackets 
to the chassis. 
26.  Remove 
the nuts  retaining the brackets  to the 
mounting  rubbers and remove the brackets. 
27.  Lower  the hoist  sufficiently  to allow  the transfer 
lever  to clear  the transmission  tunnel aperture. 
28.  Disconnect 
the four-wheel  drive indicator  electrical 
lead  (bullet  connection). 
29.  Remove  the cleat  retaining  the reverse  light...

LT77 FIVE SPEED GEARBOX (37 I 
61. Fit the  handbrake cable using a new  split  pin to 
secure the  clevis pin. Grease  the clevis  and tighten 
the outer  cable lock nuts. 
62.  Connect the  speedometer  cable. 
63.  Check  that 
the three  drain plugs  are tight  and 
remove  the main  gearbox  and  transfer box filler 
level  plugs. 
Fill the main  gcarbox  with 
approximately 
1,76 litres (3 pints)  of a 
recommended oil or until it begins to run  out of the 
filler  level  hole. Fit  and  tighten...

171 LT77 FIVE SPEED GEARBOX 
ST542M 
11. Using  tools 186705  and 186705-1A remove the 
oil  seal  collar. 
/ 12 
ST543M 
12. Remove  the ten bolts  and spring  washers  securing 
the  rear  cover  to the  gearcase;  withdraw 
the rear 
cover  and discard  the gasket. 
13. 
Fit two  dummy  bolts (8 x 35 mm) to the  casing to 
retain  the centre  plate to the  main  case. 
14.  Remove  the oil seal  collar 
‘0’ ring  from  the 
mainshaft. 
15.  Withdraw  the 
oil pump drive shaft. 
16.  Remove  the two...

LT77 FIVE SPEED GEARBOX 
31. Remove the dummy  bolts and carefully lift the 
gearcase,  leaving the ccntre  plate and gear 
assemblies  in position.  Discard gasket. 
32.  Insert  two slave  bolts and nuts  to retain 
the centre 
plate 
to the  stand;  and remove the circlip,  pivot 
pin,  reverse  lever and slipper  pad. 
33. Slide the reverse  shaft rearwards  and lift off the 
thrust  washer,  reverse gear and reverse  gear 
spacer. 
34.  Lift 
off the layshaft  cluster. 
35. Remove  the input  shaft...

LT77 FIVE SPEED GEARBOX 
Mainshaft 
42. Remove the centre  bearing  circlip. 
43.  Using  press 
MS47 and  any suitable  metal  bar, 
remove  the  centre  bearing, first gear  bush,  first 
gear  and needle  bearings  and  first gear 
synchromesh  cone. 
Input shaft ST 
44. If a difficulty  is experienced in removing  the first 
and  second  gear synchromesh  hub, locate 
underneath 
the sccond  gcar with a suitablc  tool; 
and  extract  the  complete  synchromcsh hub and 
second  gear assemblies  using...