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, pin and  fifth  speed 
selector  pin. If 
it is required  to replace  the first 
and  second  selector  fork on its own,  press  out the 
fifth  speed  gear selector  pin and  remove 
the first 
and  sccond  selector  fork from  the selector  rail. 
* . .. 
Gear selector  housing - Latest models 
66. Remove the roll pin and  release  the bias  spring. 
67.  Remove 
the two  adjusting  screws and locknuts. 
68.  Remove  the gear  lcvcr 
cxtension, secured  by a 
nut  (with 
phi n wash  er) . 
69. Remove  the bolt  and special  lock washer  to 
release 
the gear  lever  shaft from  the trunnion 
housing. 
70.  Remove  the 
four bolts and spring  washers 
retaining  the gear  lever  housing  to the  selector 
housing.  Lift 
off the housing  and discard  the 
gasket. 
(a) Rcmove  the gear  lever  gaiter  and three  bolts 
holding 
the gear  lever  retaining  plate and 
anti
-vibration  pad. 
(b)  Remove  gear lever  from the gear  lcvcr 
housing. 
(c)  Removc  the four  bolts  and spring  washers 
retaining 
the gcar levcr housing  to the 
selector  housing.  Lift off the  housing  and 
discard  the gasket. 
(d)  Remove  the bolts  and washers  retaining  the 
fifth  gcar  plunger  assembly.  Care must be 
taken  not to lose  the shims  located 
on the 
plunger  assembly  casting. 
(e)  Withdraw  the asscmbly  from the selector 
housing  and label  components  for 
identification 
on reassembly. 
71.  Rcmove 
thc bolts  and washcrs  retaining  the 
reverse  gear plunger  assembly.  Care must be 
taken  not to lose 
the shims  located on the 
assembly  casting. Detach from the selcctor 
housing  and label  components  for identification. 
72.  Remove 
the locating  bolt from the housing  for 
nylon  bush.  Pull the selector  shaft rearwards  and 
remove 
the trunnion  housing. 
73.  Release  the circlip  and detach  the nylon  insert 
from  the trunnion  housing. 
74.  Invert  the gear  selector  housing and 
removc the 
fifth  gear 
spool retainer  bolts and spring  washers. 
Lift  off the 
fifth gear  spool  retainer. 
75.  Remove  the large  blanking  plug at the  rear  of 
the 
housing . 
76. Remove  the reverse  switch blanking  plug. 
77.  Place  the gear  selector  housing into protected  vice 
jaws,  using 
a suitable  pin punch,  drift out the 
selector  yoke 
roll pin. Push the selector  shaft 
forwards  and remove  the selector  yoke. Remove 
housing  from vice. 
.# ./ 
ST548M 77 
78. Remove  the selector yoke roller  circlip  and 
79.  Withdraw  the gear  selector  housing shaft out 
80. Remove  and discard  the gear  selector  shaft ‘0’ 
7 
withdraw  the pin  and  rollers. 
through  the large  blanking  plug orifice. 
ring.  
						

							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  assemblies. If 
there  is evidence  of chipping 
or excessive  wear, 
install  new parts on reassembly. Check  all slippers 
and  slipper  rings for wear 
or breakage.  Replace 
with new 
parts if necessary. 
87. Inspect  all circlip  grooves  for burred  edges. If 
rough or burred,  remove condition  carefully using 
a fine file. 
58. Ensure all oil outlets  are clear  of sludge or 
contamination  especially the mainshaft  oil  ways. 
Clean  with compressed  air observing  the 
necessary safety  requirements. 
89. During the rebuild operation, it is recommended 
that new roller and needle bearings  are fitted. 
ASSEMBLY 
ST549M 
Reverse  gear plunger  assembly 
83. Remove  the plug,  long  spring  and  detent ball 
from the reverse  gear plunger  assembly. 
84. Detach  the circlip  which  retains the reverse  gear 
plunger,  pull 
out the plunger  followed  by the 
short  spring. 
Labcl all parts  and keep separate 
from  the 
fifth gear plunger  assembly. 
ST550M 
Cleaning  and inspection 
85. Clean  gearcase  thoroughly  using a  suitablc 
solvent.  Inspect  case  for cracks,  stripped  threads 
in the  various bolt holes,  and machined  mating 
surfaces  for  burrs,  nicks or any  condition  that 
would  render  the  gearcase 
unfit for  further 
service. If threads are stripped,  install Helicoil, or 
equivalent inserts. 
8 
Layshaft 
90. Using  tools MS47 and a suitable  tube, fit new 
bearing cones to the layshaft. 
Synchromesh  assemblies 
91. With the outer sleeve  held, a push-through load 
applied to the outer face of the synchromesh  hub 
should  register  8,2 to 
10 kgf m (18  to 22 Ibf ft) to 
overcome the  spring detent in either direction. 
92. Assemble  the  first and second  synchromesh 
asscmbly  by locating  the shorter 
splincd face 
towards  the second  gear. 
92 
ST551M  
						

							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 other  two slippers. 
95. Refit  the fifth synchromesh  hub assembly  again 
ensuring the 
hookcd ends  of the  rings  are located 
in  the  same  slipper,  but  running 
in opposite 
dircctions. Fit the backplate onto the rear  of the 
synchromcsh  hub asscmbly.  Ensure 
the tag on the 
backplate locates 
in the  slot  on the hub. 
96.  Check 
the wear  between all the  synchromesh 
cones  and  gears by pushing  the 
conc against the 
gear and  measuring  the gap between  the gear and 
cone.  The minimum  clearance  is 
0,64 mm 
(0.025 in). If this clearance  is not  met, fit new 
synchromesh cones. 
ST553M 
First gear bush end-float 
97.  Manufacture  a spacer to the dimensions provided 
in the  illustration,  this will represent a slave 
bearing 
. 
10 
38.3 m m 
+0-005 
-0-000 
ST531M 
 53-0mm 
\? 0.10  
16-52 mm 
+ 0-005 
- o*ooo 
98. Lubricatc the  second  gear needle  bearing with a 
light 
oil and fit the  bearing,  second gear and 
synchromcsh  cone to the mainshaft. It should  be 
noted  that the second  gear synchromesh  cone has 
larger  slipper  slots  than  the  other synchromesh 
cones. 
99. Fit thc first and second  synchromesh  hub 
assembly  with the selcctor  fork annulus  to the  rear 
of  the  mainshaft. 
100. Fit the  first  gear  bush  and slavc bcaring  spacer 
and  a  new circlip  to  the mainshaft.  When  fitting 
the  circlip,  care must  be taken  to  ensure 
it is not 
opened  (stretched)  beyond  the minimum 
necessary 
to pass  over the shaft. 
101. Press  the slavc bearing  spacer back against  the 
circlip  to allow  the bush  maximum  cnd
-float. 
Measure  the clearance  between  the  rear  of 
thc 
first gear  bush  and front  face of the slave bearing 
spacer  with a  feeler gauge.  The clearance  should 
be  within 
0,005 to 0,055 mm.  The first gear  bush 
is  available  with  collars 
of diffcrcnt thickness. 
Select  a bush  with a  collar 
to givc the required 
end
-float.  The bush  must  be free  to rotate  easily 
with the required cnd-float. 
102. Remove  the circlip, slave  bearing spacer and  first 
gear  bush  from  the mainshaft. 
103.  First  gear  bushcs  are available 
in the following 
sizes: 
Part 
No. Thickness (mm) 
FRCS243 40,16 - 40,21 
FRC5244 40,21 - 40,26 
FRC5245 40,26 - 40,31 
FRC5246 40,31 - 40,36 
FRC5247 40,36 - 40,41 
104. Having  selected  a  suitable first gear  bush, 
lubricate  the  needle  bearing  and 
fit to the  first 
gear. 
105. Fit the  selected  bush to the first gear  and placc 
11131 gw1 >yIICIIIuIIIG>II CUIIG;, 1uIIuwGu uy LIIL 11131 
gear assembly to the mainshaft. 
106.  Using  tools 
MS47, 18G47BA and 18G47BA-X 
refit the centre  bearing  and circlip to the 
mainshaft. 
107.  Invert  the  mainshaft, 
lubricatc the third  gear 
needle  roller bearing  with  light  oil, 
fit to the  front 
end  of the  mainshaft. 
C--+ ---- -..--L-,.---l. C,.ll,...,nA h., +ha F:.-c+  
						

							~~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 the  input  shaft bearing  using tools MS47, 
new pilot  bearing  track to the  input  shaft. 
18G47BA and 18G47BA-X. 
Reverse Gear and  Shaft 
113. Fit a new  circlip  to the  rear  of the  reverse  idler 
gear,  ensuring  that the circlip  is not  stretched 
beyond  the minimum  necessary to pass  over  the 
I shaft. 
114. Lubricate with light oil and fit both  needle  roller 
bearings. 
Fit the  shorter necdle bearing  to the 
rear  of the  reverse  idler gear. 
115. Fit a new circlip to the front  of the  reverse  idler 
gear. 
* 
Extension case 
116.  Using  a suitable  press, fit a new  fcrrobcstos  bush 
to the case,  ensuring thc two drain  holes are 
towards 
thc bottom of the  case. 
/- ._.-. 
/i I h Y  C. I 1 . ST554M 
117.  With  the aid of tool 18G1422, fit a new  oil seal  to 
the rear  of the  extension  case. Ensure  the seal  lips 
are  towards  the ferrobestos  bush. Lubricate 
thc 
seal lips with  a suitable SAE 140  oil. 
118. Assemble  and fit the fibre  oil pump  gears to the 
oil pump  cover,  whilst ensuring  the centre  rotor 
squared  drive faces 
the layshaft. 
119 
k 
Q@ 
117 
ST555M kz2 
119. Fit the  three  bolts and spring  washers  to secure 
the  oil pump  covcr;  and tighten  to 
thc specified 
torque. 
120. Ascertain  that the oil pick  up pipe  is free  of 
contamination 
or blockage. 
121. 
Fit a  new  oil filter,  fibre gasket  and tighten  plug to 
the  specified  torquc. 
Centre plate 
122. Fit the ccntre  platc to a suitable  stand and secure 
123.  Place  the new  mainshaft  and layshaft  bearing 
124.  Lightly  lubricate  the selector  shaft with a light  oil. 
125.  Take  the selector  shaft complete  with the first  and 
second  selector  fork, front spool  and third  and 
fourth  selector  fork; engage  both selector  forks 
in 
their respective  synchromesh  slccvcs on thc 
mainshaft,  simultaneously  engaging the sclcctor 
shaft  and mainshaft  assemblies 
In the centre  plate, 
whilst  rotating  the 
fifth gear selector  pin to align 
with  the slot 
in the  centre  plate. 
with 
two slave  bolts. 
tracks  to the  centre  plate. 
126. 
Fit the  layshaft to the centre  plate. 
127. Rotate the wler!or shaft and spoo! to emb!e !he 
reverse  crossover  lever forks to correctly  align to 
the reverse  pivot  shaft. Reposition the selector 
shaft  and locate  the lever  between  the fork 
on the 
reverse  gear pivot  shaft.  Insert pivot pin and 
fit a 
new  circlip,  ensuring  that it is  not  opened  beyond 
the  minimum  necessary 
to pass over  the shaft. 
11  
						

							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  from 
the underside  of the  centre  plate, 
ensuring  the roll  pin 
is aligned  with the slot in thc 
centre  plate casing. 
12 
spring  with light  oil, and fit to the  top of centre 
130. 
Prior  to assembly  lubricate the detent  ball and 
plate.  Smear  Hylomar  PL32 or Loctite 
290 to the 
plug  threads  and screw  the plug  flush  with the 
case.  Stake  the plug  to 
prevcnt rotation  using a 
suitable  centre punch.  Release  the 
slave bolts. 
131.  Locate  the fourth  gear synchromesh 
cone to the 
third/fourth synchromesh  assembly. 
132.  Fit the  input  shaft to the  mainshaft. 
133.  Fit the  reverse  gear spacer 
to thc reverse  gear 
134. Fit a new  gasket to the centre  plate. 
shaft. 
Main 
gearbox  casing 
135. Insert  a new  plastic  oil trough  to the  back  of the 
main  gearbox  casing, ensuring 
the open trough 
faces  the top 
of the case. 
136.  Carefully  lower the gearcase 
into position  over 
the gear assemblies. DO NOT USE FORCE. 
This  operation  can be assisted  by the  use  of two 
8 
x 100 mm guide  studs.  Ensure  the centre  plate 
dowels  and selector  shaft arc 
engaged in their 
respective  locations. 
137.  Fit the  layshaft  and input  shaft bearing  outer 
tracks. 
138.  Using 
8 x 35 mm slave  bolts and plain  washers to 
prevent  damaging the rear face of the centre 
plate,  evenly  draw the gcarcase 
into position  on 
the  plate. 
139. 
Fit the  locating  shaft front  spool to the top of the 
gearcase  using Hylomar  PL32 to seal  between  the 
spool  and gearcase.  Smear Loctite  290 or 
Hylomar  PL32 
to the bolt  threads,  tighten bolts 
and  spring  washers 
to the specified  torque. 
140.  Manufacture  a layshaft  support  plate and plain 
washer  to the  dimensions  provided in the 
illustration. 
ST1118M 
141.  The layshaft  support plate is fitted  using two 8 x 
25 mm bolts  and washers  to the  front of the -- 
gearbox,  with the plain  washer  situated  between (-:; 
the support  plate and layshaft.  The plate  also 
retains  the input  shaft bearing  outer track.  
						

							~~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 
prevent  damage  to  the  adjacent  bearings  when 
deforming the nut  locking collar, support  the 
fifth 
gear with a block of timber.  Using a round  nose 
punch  carefully  form  the collar  into the layshaft 
grooves,  as illustrated. 
I* 
* . ... , 
143. Locate  assembly horizontally in a vice or suitablc 
jig. 
144. 
Fit thc fifth speed washer, roller bearing,  gear and 
cone  to the mainshaft. 
145.  Press 
fit fifth gear  synchromesh  hub assembly 
using  tool 
1861431. Fit a  dummy  spacer with  an 
oversize  bore 
to ascertain thc correct spacer to 
provide  the specified  clearance  on the  fifth  gear. 
When  fitting,  care must  be taken 
to ensure  the 
hub  assembly  and selective  spacer are NOT 
pushed  too far on the  mainshaft.  Only 
fit with 
sufficient  clearance  to allow  the circlip  to  engage 
ST amu 
146. Measure the clearance  between the  front  spaccr 
and  fifth  gear  (driven),  which should  be between 
0,005  and 
0,055 mm. Select  the appropriate 
spacer  to provide  the aforementioned clearance.  Part 
No. Thickness 
Part No. Thickness 
FRC5284 5,lO FRC5294 5,40 
FRC5286 5,16 FRC5296 5,46 
FRC5288 5,22 FRC5298 5,52 
FRC5290 5,28 FRC5300 538 
FRC5292 5,34 FRC5302 5,64 
(1 (n1m) 
147. Fit the correct selective  spacer and new circlip. 
Mainshaft and layshaft end-tloat 
148. Measure  and adjust the mainshaft  and layshaft 
end
-float as necessary.  Remove  the  layshaft 
support  platc 
from the front of the gearbox. 
Part 
No. Thickness  Part No. Thickness 
(> () 
FRC4327 
FRC4329 
FRC433 1 
FRC4333 
FRC4335 
FRC4337 
FRC4339 
FRC4341 
FRC4343 
FRC4345 
FRC4347 
131 
137 
1,63 
1,69 
1,75 
1,81 
137 
1,93 
1,99 
2,05 
2,11 
FRC4349 
FRC435 1 
FRC4353 
FR C43 5 5 
FRC4357 
FRC4359 
FRC4361 
FRC4363 
FRC4365 
FRC4367 
FRC4369 
2,17 
2,23 
2,29 
2,35 
2,41 
2,47 
2,53 
2,59 
2,65 
2,71 
2,77 
149.  When ascertaining thc mainshaft end-float care  must 
be  taken  when checking  the  dial gauge  readings 
10 
ensure  that  the  end-float  only,  as distinct  from  side 
movement,  is recorded. 
To overcome the  difficulty in 
differentiating betwecn end-float and side movement, 
wrap  approximately ten  tums of masking  tape around 
the  plain  portion 
of the  input  shaft  below the splines. 
Ascertain  that 
the rise and  faii of the  input shaft is not 
restricted  by the  tape. 
150.  Place  a mainshaft  and layshaft  spacer 
of nominal 
thickness  1.02 
mm on the mainshaft  and layshaft 
bearing  tracks, 
fit the  front  cover  and  gasket  tighten 
bolts and spring washers  to the  specified  torque. 
151. Invert the gearbox on  the stand. Rotate the mainshaft 
to correctly seat  the bearing. 
13  
						

							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 dial  gauge  and ball  bearing. 
Rotate  the layshaft  to correctly  seat the bearing. 
Place  a suitable  ball bearing  in the  layshaft  centre 
and  mount 
the dial  gauge  on the  gearcase,  with 
the  stylus  resting  on the  ball  bearing  centre. Zero 
the  gauge. 
I I ll Ill 
156. 
157. 
14 
, With  the aid of levers  approximately 23 cm long; 
to  prevent  component  damage, check 
the end- 
float by a gentle  push-lift action  to the  layshaft. 
The  required  layshaft setting 
is: 
0,025 mm end-float 
0,025 
mm preload. 
Spacer  thickness  required equals; nominal 
thickness  of spacer,  plus end
-float  obtained. 
Remove  the gauge  and ball bearing. 
Remove  the front  cover.  Having  ascertained  the 158. 
Fit a 
new  oil seal to the front  cover,  ensuring  the 
seal  lips face  towards  the gearbox.  Lubricate  the 
scal lips with SAE 140 gear  oil. 
159.  Mask  the splines  with masking  tape to protect 
the 
oil  seal.  refit the front  cover  and remove  the 
spline  masking  tape. 
160.  Refit  the bolts  and spring  washers  having used 
Hylomar  PL32 or Loctitc  290 on the  bolt  threads. 
Tighten  to 
thc specified  torque. 
161.  Remove  gearbox from the stand  and place 
suitably  supported  on the  bench.  Remove  the 
guide  studs fitted  to the  centre  plate. 
162.  Select  reverse  gear by turning  the selector  rail 
anti
-clockwise  and pulling  rearwards.  Move the 
fifth  speed  synchromesh  hub into 
mesh with  the 
fifth  gear.  Tighten  the staked  nut onto  the 
fifth 
gear layshaft  to the  specified  torque. Stake the nut 
with 
a suitable ounch to  secure.  Select neutral bv 
pushing  selector  rail inwards  and turning 
clockwise,  thereby returning  the fifth  speed 
synchromesh  hub 
to its out  of mesh  position. 
Fifth gear selector fork assembly 
163.  Fit the  fifth  speed  selector  fork and bracket  to the 
fifth gear  synchromesh  hub assembly, cnsuring 
that the largest  groove  lip is facing the rear of the 
gearbox. 
164. 
Fit the  fifth  gear  spool to the selector  shaft, rotate 
and  engage 
the selector  fork into the groovc. It 
should  be noted  that the longer  shoulder  of 
thc 
spool is fitted towards  the front  of the  gearbox. 
165. 
Fit the fifth  speed  sclector  fork brackct bolts and 
spring  washers.  Tighten to specified  torque. 
164 
165 
mainshaft  and layshaft end-float,-fit the mainshaft 
and  layshaft  spacers of the  appropriate  thickness 
ST56,M to the  mainshaft  and layshaft  bearing tracks. 
166. Fit a new circlip  to the  selector  shaft ensuring  that 
Selective  spacers are available  in a range of sizes it is  not  expanded  beyond the minimum  necessary 
to  meet  the aforementioned  clearance limits. 
to obtain  entry. 
Part 
No. Thickness  Part No. Thickness 
167. Remove  the six dummy  bolts securing  the centre 
TKC4633 1,69 TKC4649 2,17 168.  Position thc gearbox  assembly  horizontally  and fit TKC4635 1,75 TKC4651 2,23 
TKC4637 1.81 TKC46.53 2.29 
plate to the naiii casiiig. () () 
the oil pump shaft to the  pump. 
TKC4639 1187 TKC4655 2135 
TKC4641 1,93 TKC4657 2,41 
TKC4643 1,99 TKC4659 2,47 
TKC464S 2,05 TKC4661 2,53 
TKC4647 2,11 TKC4663 2,59 
Extension case ..%. e. +j 169. Fit a new  gasket to the centre  plate. k -9 170. Rotate  the oil pump  to align  with the oil pump 
drive  shaft.  
						

							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 
rearwards  to select 
a neutral  position. 
175.  Cover 
the mainshaft  splines with masking tape 
and 
fit a new oil seal  collar ‘0’ ring.  Remove  the 
masking  tape. 
176.  Using  tool 1861431 
fit the oil seal  collar  to the 
mainshaft,  ensuring 
the collar is NOT pushed  too 
far  on the  shaft,  fit only 
with sufficient  clearance 
to allow the circlip  to engage in its  groove. 
177. 
Fit a new  gasket  to the  top of the  fifth  gear 
extension  case and 
fit the gear  change  housing  by 
engaging  male selector  yoke with the female 
yoke.  Align the housing  locating dowels and refit 
the  housing.  Secure with the three  bolts and 
washers;  and tighten  to the  specified  torque. 
.. . . ..d :. : .. 
-. .. ,‘ I  ~ .. 
37 
Bell 
housing 
178.  Locate  the bell  housing  to the  dowels  and fit the 
two long  bolts  (12 x 45 mm) with spring  and plain 
washers  to the  dowel  positions. 
Thc remaining 
four bolts (12 x 30 mm)  are fitted  with spring 
washers  only. Tighten  to the  specified  torque. 
I. 178 
ST562M 180b 
1. : L ^’ I ’ 179. Fit the  clutch  release  lever  pivot and securc with 
the bolts  and spring  washers.  Tighten to the 
specified  torque.  180. 
Prior to reassembly, 
lubricate the following with a 
thin film of molybdcnum disulphide  grease: 
(a) Clutch release  lever fulcrum  pivot socket. 
(b) 
The clutch  release  lever slipper  pad pins  and 
(c)  Ball  ends  of the  clutch  opcrating  push rod. 
181.  Refit  the slipper  pads to the  clutch  release  lever 
and  locate  the lever  socket  to the  clutch  release 
lever  pivot. 
182.  Lubricate  the inner  face of 
thc clutch release 
bearing  carrier with molybdenum  disulphide 
grease  and 
fit to the  front  cover  spigot,  locating 
the  clutch  release  lever slipper  pads to the  carrier 
recesses.  the 
faces 
of cach slippcr pad. 
183. Fit a new nylon  clutch  release  carrier clip. 
184. Refit the gearbox  oil level plug, and tighten  to the 
185. Refit  the gearbox  oil drain  plug and fit ncw fibre 
specified 
torque. 
washer.  Tighten plug 
to specified  torque. 
Reverse gear plunger  assembly 
186. Lubricate  the  short spring and plunger with BP 
Energrease L2 or similar  prior to assembly. 
187. 
Fit the short  spring  into the plunger  base and slide 
the  assembly  into the 
rcvcrse gear  plunger 
housing.  Fit a new  circlip  to retain 
the plunger. 
Ensure  the spring  is not  trapped,  the detent 
groove  should be 
fully visible down the detent 
hole. 
188.  Lubricate 
the detent  ball with  light oil and fit into 
its  bore. 
189. Refit  the long  spring  and plug,  coat the plug 
threads  with Loctite  290 
or Hylomar PL32, and 
tighten  to the  specified  torque. 
The following  instructions (190 to 21 I) relate to the  early 
model  gearbox  with 
a spring-loaded plunger for fifth 
gear  selection. 
Fifth  gear plunger  assembly 
- Early models  only 
190. Lubricate  the short  spring  and plunger  with BP 
Energrcase  L2 or similar, prior to assembly. 
191. Fit the short spring in thc plunger  base and slide 
the  assembly  into the fifth  gear plunger  housing. 
Fit a new  circlip  to retain  the plunger.  Ensure the 
spring 
is not  trapped, the dctent  groove  should be 
fully 
visiblc down  the detent  hole. 
192.  Lubricate  the dctent  ball with  light  oil and 
fit into 
its  bore. 
193.  Refit  the long  spring  and plug,  coat the plug 
threads  with Loctite  290 
or Hylomar PL32, 
tighten to the  specified  torque. 
Gear selector  housing -Early models 
194. Refit the gear selector  rollers, pin and  new  circlip 
ensuring  circlip is not  expanded  beyond minimum 
necessary  to obtain  entry. 
195. Lubricate  the gear  selector  housing shaft with 
light oil and fit a new ‘0’ ring. 
15  
						

							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.  Refit  the 
fifth gear spool  retainer,  coat the bolt 
threads 
with Loctite  290, and tighten  the bolts  and 
washers 
to the  specified  torque. 
200.  Fit a new  nylon  insert  into 
the trunnion  housing 
and  secure  with a new  circlip. 
201.  Invert  the gear  sclector  housing and 
fit the 
trunnion  housing 
to the selector  shaft, ensuring 
the  locating  bolt aligns  with 
the shaft indent.  Coat 
the  bolt  threads  with Loctite  290. Tighten  bolt to 
the  specified  torque. 
202.  Fit a new  gear  lever  housing  gasket and 
fit the 
gear  lever  housing,  spring washers  and bolts. 
Tighten  bolts 
to the specified  torque. 
203.  Coat  the upper  and lower  balls of the  gear  lever 
shaft  with 
BP Energrease  L2 or similar. Push 
lever  into the trunnion  nylon bush. 
204.  Place 
new vibration  pad over  the gear  lever  and fit 
the gear  lever  retaining  plate. Refit the three 
shouldered  bolts and tighten  to the  specified 
torque. 
205. Refit  the gear  lever  gaiter  and attach  the gear 
lever  extension.  Then carry out the following 
procedure  to ensure  a clearance  of 0,3  to 0,9 
mm 
between  the gear  lever  yoke and stops. 
206.  Select  first or second  gear. It may  be necessary  to 
rotate  the mainshaft  whilst manipulating  the gcar 
lever. 
297. Locate tne reverse  gear piunger on the  right  hand 
side  viewed  from the rear,  giving  sufficient  load 
on  the  trunnion  to eliminate  side play.  Whilst 
maintaining  a 
light finger pressure,  measure the 
clearance  between the plunger  assembly  casting 
and  gear  selector  casting.  Add 
0,6 mm to the 
measured  figure and select  suitable  thickness 
shims 
to equal  the total. 
16 
208. Remove  the reverse  plunger  assembly, fit the 
required  thickness 
shim(s) refit the plunger 
assembly,  spring washers  and bolts.  ‘Tighten  bolts 
to the specified  torque. 
209.  Select  third 
or fourth  gear. 
210.  Locate  the fifth  gear  plunger  on the  left  hand  sidc 
viewed  from the rear,  giving  Sufficient  load 
on the 
trunnion  to eliminate  sideplay. Whilst 
maintaining  a light  finger  pressure,  measure 
the 
clearance  between the plunger  assembly  casting 
and  gear  selector  casting.  Add 
0,6 
nim to the 
measured  figure and select  suitable  thickness 
shims  to equal  the total. 
211.  Remove  the 
fifth gear plunger  assembly  and fit 
the required shim(s), refit  the plunger  assembly, 
spring  washers  and bolts.  Tighten  bolts to 
the 
specified  torque.