Land Rover Defender 90 110 Workshop Book 3 Rover

~~77 FIVE SPEED GEARBOX 137 I 
Gear selector  housing - Early models (Not illustrated) 3- - ;c ::: Centre  plate .&&L\.S v,, 62. Remove  the layshaft  and mainshaft  bearing tracks 
from  the centre  platc and reverse  pivot post. 
Main  gearbox  casing 
63. Remove  the mainshaft  and layshaft  bearing tracks 
64.  Remove  the plastic  oil trough  from 
thz front of 
from the main  casing. 
the casing. 
Selector  rail 
65. The  selector  rail is supplied  complete with first 
and  second  selector  fork,...

LT77 FIVE SPEED GEARBOX 
Fifth gear plunger  assembly - Early models  only 
81. Remove  the  plug,  long  spring  and detent  ball 
from  the 
fifth gear plunger. 
82.  Remove  the circlip  which  retains the 
fifth gear 
plunger,  pull out  plunger  and  short spring.  Keep 
all  parts  labelled  and separated  from the reverse 
 plungerassembly. 
82 
86. Inspect all gear teeth for chipped or broken teeth, 
or  showing  signs of excessive  wear. Inspect 
all 
spline  teeth  on  the  synchromesh...

LT77 FIVE SPEED GEARBOX I37 I 
KEY 
1. 
2. 
3. 4. 
5. 
6. 
6A. 7. 
8. 9. 
10. 
10A. 11. 
T. .. 
.. 
9  

37 
93.  Refit the slippers  and locate  the slipper  rings to 
each side of the assembly,  ensuring  that  the 
hooked  ends  of both  slipper  rings are located  in 
the  same  slipper;  but  running  in opposite 
directions  and finishing  against 
the other two 
slippers. 
LT77 FIVE SPEED GEARBOX 
93 
ST552M 
94. Assemble  the third  and  fourth  synchromesh 
assembly  and  ensure  the  hooked ends  are located 
in the same slipper; and  run in opposing directions 
and  finally  locate against  the...

~~77 FIVE SPEED GEARBOX 137 
..\./I. ,,-:,A .. . .,.. . ,_ . .I ,4. I. .. .. ., 
108. Fit the  third  gear to the  mainshaft;  and locate  the 
third  gear synchromesh  cone 
to the third  gear. 
109. 
Fit the thirdlfourth synchromesh  assembly (with 
the  longer  box 
of the synchromesh  hub to the 
front  of the  gearbox)  to the  mainshaft. 
110.  Fit the  spaccr  and bearing  to the  front  of the 
mainshaft. 
?.,z,x: :i 
Input shaft 
111.  Using  tool MS47  and any suitable  tube, refit a 
112. 
Fit...

El LT77 FIVE SPEED GEARBOX 
126 
128. Fit the slipper  pad to the  reverse  lever. If a new 
reverse  lever pivot  shaft has been 
fittcd, it will be 
necessary  to ascertain  that its radial  location  is 
consistent with the reverse  pad slipper 
engagementklearance. The radial  location  is 
determined  during initial assembly. 
ST557M 129 
U 
129. Fit the  reverse  gear spacer  and reverse  gear 
assembly,  locating the slipper  pad lip to 
the 
reverse  gear groove.  Engage the reverse gear 
shaft...

~~77 FIVE SPEED GEARBOX 137 
L ~ 
,?-:;a. . 1. 
,.,E*.a . i 
142. 
On early models:  With the aid of a suitable  press, 
fit  the  fifth  gear,  collar  and  new circlip  to the 
layshaft. 
Later models: Fit the  fifth  gear  to the  layshaft 
using  a  suitable  press  and  loosely 
fit a NEW 
special nut. To tighten  the  nut,  hold the gearbox 
firmly  in  a Vice  and 
if necessary  use a flange 
holding  wrench to restrain  the  gearbox. Tighten 
the nut to 204  to 231 Nm (150  to 170 Ib ft). To...

14 LT7 FIVE SPEED GEARBOX 
152. 
153. 
154 
155 
Place  a suitable  ball bearing in the mainshaft 
centre  and mount  the dial  gauge  on the  gearcase 
with  the stylus  resting 
on the ball  bearing  centre. 
Zero  the gauge. 
Check  the end
-float  by a push-pull action to the 
mainshaft.  The required  mainshaft  end-float 
measurement  should be between 
0,06 to 0,Ol mm 
with  no pre-load. 
Spacer  thickness  required equals; Nominal 
thickness 
of spacer,  plus end-float  obtained. 
Remove 
the...

LT77 FIVE SPEED GEARBOX 
c:;;:p$ 171. Carefully fit the extension  case ensuring  that the 
oil  pump  shaft engages  the layshaft. 
172. 
Fit the extcnsion case  bolts  and spring  washers; 
tighten  to specified  torque. 
173.  Using 
a large  screwdriver,  ease the selector  shaft 
forwards  to selcct  a gear.  It may  be found 
necessary  to rotate  the mainshaft  to ease  gear 
selection. 
174. 
Fit the  selector  yoke to the  selector  shaft and 
secure  with 
a new roll pin. Pull selector  shaft...

El LT77 FIVE SPEED GEARBOX 
196. Insert  shaft through  the large  blanking  plug 
orifice,  ensuring  the shaft  indent  is uppermost. 
197.  Place  the gear  selector  housing into protected  vice 
jaws  and 
fit the selector  yoke to the shaft,  using a 
suitable  pin punch  and new 
roll pin.  Remove  the 
housing  assembly  from the vice  on completion. 
198.  Fit the  reverse  switch and large  blanking 
plugs. 
Coat plug threads  with Loctite  290 and  tighten  to 
the specified  torque. 
199....