Land Rover Defender 90 110 Workshop Book 3 Rover

~~85 FIVE SPEED GEARBOX 1371 
.:i : . i.; ..., -;.::. ..:, ..:.?:, , ... .. .. ... , 
1st gear to bush end float  5th gear end float 
7. Fit 5th  gear  thrust  washer,  5th gear,  needle  bearing 
and  spacer  followed  by synchromesh  unit but 
leaving  out the baulk  ring at this  stage.  Press down 
on the synchro  inner member  and chcck the gear 
end 
float as  shown; this tolerance,  again is identical 
to  3rd  gear. 
5. To carry out 1st gear  check,  it is  not  necessary to 
assemble  the...

37 
Lay shaft  REASSEMBLING GEARBOX 
1. Remove layshaft rear bearing  inner race. 
2. Fit layshaft  to vice  and lever off front  bearing  inner Input shaft,  mainshaft  and layshaft 
track. 1. Position  front bearing p!ate on suitable  stand and 
fit input shaft into bearing. 
2 
LT85 FIVE SPEED GEARBOX 
SI 
3. Clean  layshaft,  bearings  and tracks and check for 
wear. 
2. Secure  bearing  plate in vice, fit original  selective 
washer  and retain  with 
circlip. 
3. Measure  the clearance  between...

LT85 FIVE SPEED GEARBOX 
,.._ .. . . .... ,:,:.,i., .. .. 10. Lower mainshaft  assembly into input shaft at the 
same  time rotating  to engage  baulk 
ring slots and ., ;- , ., . , .. 
lugs. 
I 1. Engage  3rd gear. 
12. Fit layshaft  assembly  to front  bearing  plate and 
mesh with mainshaft. 
37 
15. Fit guide studs 18G 1294 to gearbox. 
NOTE: Take  care to ensure  that the front  layshaft 
bearing  rollers are not  put out of alignment,  then 
return 
3rdl4th synchro  hub to neutral. 
ia 
-1 2...

. 
37 LT85 FIVE SPEED GEARBOX 
21. Fit layshaft rear bearing  (identification  numbers to 
rear)  dummy  spacer, and 
rctain temporarily with 
layshaft nut. 
22. Remove  guide studs 18G 1294. 
23.  Temporarily 
fit two  bell housing  bolts with spacers, 
to  secure  front bearing  plate to gearbox. 
24. Remove Tool Nos. 18G 1431 and LST 1431-1 and 
then  check  that 
the mainshaft  is engaged  through 
bearing  sufficiently 
to fit mainshaft  bearing circlip. 
25. Remove  screwdriver  from reversc shaft...

LT85 FIVE SPEED GEARBOX 1371 
Selector rails and forks 
56. Locate 5th gear  fork and bracket on to synchro  hub 
57. Secure fork bracket to gearbox  with two bolts, 
and 
gcarbox  dowels. 
plain washers and spring washers. 
. 
59. Fit lstnnd and 3rd/4th selector forks. 
58. Fit selector rail intcrlock plungers  into the cross- 
drilling in the  gcarbox  case. 60. Fit reverse cross-over lever. 
61. Insert  interlock  into lst/hd selector rail. 
81  

LT85 FIVE SPEED GEARBOX 
62. Push M2nd selector  rail through  gearbox  seating 
and  locate 
in reverse  cross-over lever  and selector 
fork; 
do not  tighten  fork clamp  bolt. 
NOTE: IstiZnd fork clamp bolt is not a set boit. 
63. Fit lst/2nd selector  jaw to rail and  align for roll pin. 
64. Using  suitable  drift, tap in roll pin to secure  jaw 
65. Repeat  operation for 3rd/4th selector rail and jaw. 
66.  Push  5th gear  selector  rail through  gearbox  scating 
67. 
Fit 5th  gear  selector jaw...

LT85 FIVE SPEED GEARBOX 137 I 
, ::,:+, 73. Fit reverse gate spring  to selector  rail and  knock- 
74. Fit detent balls and  springs. 
:::. .

1351 LT85 FIVE SPEED GEARBOX 
Bell housing 
97. Remove  bolts and spacers  securing  front bearing 
plate 
to gearbox. 
98. Fit new bell  housing  gasket. 
99. Locate bell housing  squarely  on dowels  and 
secure  housing  and front  bearing  plate 
to gearbox 
with six bolts  and spring  washers. 
Lower  gear 
leverlbias spring  housing 
100. Removc  rag from  gearbox  top cover. 
101. Lubricate  gear lever  ball and  lower  yoke. 
102. Fit lower  gear lever,  nylon cup and grommet. 
103. Fit new...

LT85 FIVE SPEED GEARBOX 1371 
3rd/4th gear selector  rail adjustment 
114.  Slacken 3rd/4th stop screw in extension  housing. 
Bias spring  adjustment 
123. Apply  Loctite  Stud and Bearing Fit (270)  to bias 
springs  screws and tighten  up until  screw  heads 
are  flush  with top face 
of bias  spring  housing. 
. _. . 
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... , ., ;.i ,;:,’;~ ”.. ... ,,.- . .I 
123 II 
115. Select  3rd gear. 
116.  Tighten 
stop screw  until it makes  contact  with 
3rd/4th selector rail. 
117. Turn back...

37 
REMOVE LT230T TRANSFER GEARBOX 
FROM 
THE LT85 GEARBOX 
LT230T TRANSFER GEARBOX 
Special tool: 18G 1425 -Guide  studs (3) 
Also, locally  manufactured adaptor  plate, see below 
Adaptor plate 
for removing  transfer gearbox 
The transfer  gearbox  should be removed  from 
underneath  the vehicle,  using a hydraulic  hoist. An 
adaptor  plate for locating  the transfer  gearbox  onto the 
hoist  can 
be manufactured  locally to the  drawing 
below.  If a similar  adaptor  plate was made  for the...