Land Rover Defender 90 110 Workshop Book 3 Rover

							.. 
LT 95 FOUR SPEED GEARBOX 
b- 
37 
REMOVE AND OVERHAUL BELL HOUSING  AND REMOVE  AND OVERHAUL  GEAR CHANGE 
CLUTCH  RELEASE  SELECTORS 
I. Withdraw the locating staple from the clutch 
2. Lift out the release  sleeve and bearing  assembly. 
3. Remove  the bell  housing  fixings and make  a note 
4. Withdraw the bell  housing  complete  with clutch 
5. If required,  remove 
the push  rod clip  and  the 
release 
slecve and 
release  lever. 
of  the  position 
of each  bolt and nut. 
release  lever. 
spring  clip and  withdraw  the clutch  release  lever. 
1. Remove  the bell  housing. 
2. Select  neutral,  remove the reverse  light switch  and 
remove 
the gearbox  top cover  and joint  washcr. 
3. Lift out the dctent  springs. 
4. Withdraw the detcnt  balls, using a small magnet or 
5. Slacken  the pinch  bolt securing  the reverse  selector 
6. Drive out the four retaining  pins until  the shafts  are 
an 
air  blast. 
finger. 
free 
in the  selectors. 
ST1225M 
Assemble  clutch release and bell housing 7. Tap  out the selector  shafts. 
6. If removed, fit the release  lever spring  clip. 
7. Apply a thin film of Unipart  Universal or other 
suitable  jointing  compound  around the three 
selector  shaft holes 
in the bell  housing  rear face. 
8. Fit the bell  housing,  locating on the  dowels. 
9. Apply a thin film of molybdcnum disulphide grease 
onto  the 
front cover  extension  sleeve. 
10. Fit thc rclcase sleeve and bearing  assembly. 
11. Fit the locating  staple to the clutch reiease sleeve 
and  lever. 
8. Withdraw  the selector  jaws and forks. 
9. Withdraw  the two  interlock  plungers from the 
cross
-drilling. 
10. Rcmove the lock-wired  pivot bolt. 
11. Lift out the reverse  cross-over lever. 
Overhaul 
Examine  all parts  and renew if worn.  Renew thc detent 
springs.  Ensure that 
the retaining  pins are an 
interference 
fit, if not,  renew. 
.. 
ST 1 
47  
						

							1371 LT 95 FOUR SPEED GEARBOX 
Assemble gear change  selectors 
12. Withdraw  the retaining  pins from  the selector  jaws. 
13. Engage the cross-over  lever  and locate  fully in the 
groove 
in the  reverse  idler with the peg  in the  top 
of  the  cross
-over  lever  fully in the selector  finger. 
14. Start the pivot  bolt in the lever  threads.  Should it 
not start properly  move the lever  away  from the 
selector  finger but not out 
of engagement  with the 
idler. 
15. Locate  the first/second gear selector  fork in the 
groove 
in the  outer  member,  with the boss  on the 
fork  to the 
rcar. Position  the boss  to the R.H. side 
of the  box. 
16. Locate  the third/fourth gear selector  fork in the 
groove 
in the  outer  member.  Position the fork  with 
the  retaining  pin entry  hole at the  top 
R.H. side. 
17. Fit the third/fourth gear  selector  shaft and 
interlock  pin assembly  and secure  to the  selector 
18. Fit the two  interlock  pins to engage  in the  grooves 
each  side 
of the third/fourth gear selector  shaft. 
19. Position  the reverse  stop hinge  plate and selector 
jaw in the gearbox,  adjacent to the third/fourth 
gear selector  jaw. 
20. Fit the  reverse  gear selector  shaft and engage  the 
selector  jaw and 
hinge spring. 
21. Push  the shaft  home  and engage  the reverse  cross- 
over lever  selector  finger. Do not secure  the pinch 
bolt  at this  stage. 
22. Secure the revcrse gear  selector  jaw to the shaft 
with  a retaining  pin. 
. fork with a retaining  pin. 
24 23 2a01 15 25 A+- +* 
ST 1227M 
23. Posi!i~n thp first,/secogd up?ir cplprtnr iaw in the b- w--Va J 
gearbox. 
24. Fit the first/second gear selector  shaft; engage  the 
selector  jaw and  selector  fork 
as the shaft is pushed 
home. 
25. Fit the  retaining  pins, fitting  the rear  pin first. 
26. Move  the reverse  shaft forward  until the selector 
jaw  abuts  the casing. 
27. Holding  the reverse  shaft  as  described in the 
previous  item, move  the reverse  selector  finger 
forward 
on the  shaft  until it abuts  the casing,  then 
move it rearward  until it is just  clear  of the  casing. 
28. Place a 0,25 mm (0.010 in)  feeler  gauge  between 
the  upper  edges of the  reverse  and 
third/fourth 
selector jaws. 
NOTE: The edges  of the  selector  jaws taper  slightly, 
therefore, 
it is important  that the feeler  gauge  is 
positioned  between the upper  edges. 
29. Hold the reverse  and third/fourth selector  jaws 
together  to retain  the feeler  gauge, 
then rotate  the 
reverse  selector  finger until it abuts  the 
third/fourth 
selector  shaft and tighten  the pinch  bolt. 
30. Wire lock the cross-over  lever  pivot  bolt. 
31. When  fitting the hinge  spring  to the  reverse  stop 
hinge,  first engage 
the large  hook  around  the 
selector  shaft, as illustrated,  before fitting the small 
hook 
to the  reverse  stop hinge  pin. 
48  
						

							LT95 FOUR SPEED  GEARBOX (371 
6. Lift out the reverse  idler gear assembly. 
7. Remove  the circlip  and plain  washer. 
8 Lift out the needle rollcr bearings  and further  plain 
washer. 
9. Withdraw the remaining  circlip. 
9 
32. Fit the  detent  balls and springs. 
33.  Selcct  neutral  and using  a new  joint  washer, 
fit thc 
gearbox  top cover  and secure  with the eight  bolts, 
T 
and evenly  tighten to the correct  torque. STl23 1 M 
34. Fit the reverse  light switch 
35.  Fit the  bell  housing. 
Assemble  reverse idler gear and shaft 
REMOVE 
AND OVERHAUL  REVERSE IDLEK 
GEAR 
AND SHAFT 
Special 
tool: 
18G1335 - extractor  for shaft 
1. Remove  the gearbox sidc cover. 
2. Remove  the gearbox  bottom cover. 
3.  Remove  the bolt  securing 
the idler  gear shaft in the 
4. Withdraw  the idler gcar shaft,  using cxti-actor 
5. Remove the ‘0’ ring seal. 
gearbox 
casing. 
18G1335. 
10. If removed, fit the shaft  support  bush, using 
Locquic  primer grade 
‘T and ‘AVV’ grade. 
11. Fit the  circlip  to selector  groove end of thc gcar. 
12. 
Fit thc plain  washer  and two  needlc rollcr bearings. 
13. 
Fit the outcr plain  washcr  and secure  with circlip. 
14. Fit a new ‘0’ ring  seal to the  idler  gear shaft. 
15. Offer  the idler  shaft to the gearbox  and align  the 
16. Smear  clean gearbox  oil onto the ‘0’ ring  seal. 
17. Position  the reverse  idler assembly in the casing. 
18. Engagc thc sclcctor foot in the  idler  gcar groove. 
19. Drive in the idler  gear shaft  until the retaining  bolt 
holes  are aligned. 
20. Before  fitting the retaining  bolt, trcat the threads 
with  Locquic  primer grade 
‘T’ and allow  to  dry. 
Then, 
fit thc bolt  using  Loctite  Studlock  grade. 
21.  Fit the  gearbox  bottom cover using a new  joint 
washer  and secure  with the fourteen  bolts evenly 
tightening  to the  correct  torque. 
22. Using a new joint washer fit the side  cover  with the 
four  bolts  and tighten  to 
thc spccificd torque. 
retaining 
bolt holes. 
. 
49  
						

							LT 95 FOUR SPEED GEARBOX 
REMOVE AND OVERHAUL FRONT COVER  AND 
OIL PUMP 
Service tools: 
R01005 - Centralising tool 
18G134 - guide and 
18G134DG - assembly tool for fitting  oil  seal  and oil 
feed ring. 
1. Lift out the retainer  staple from the clutch  release 
bearing  assembly  and 
the release lever. See clutch 
release  overhaul. 
2. Withdraw  the release  bearing  assembly. 
3. Remove  the slave  cylinder pushrod. 
4. Remove  the spring  clip. 
5. Withdraw  the clutch  release  lever. 
6. Remove  the front  cover  assembly,  complete with 
oil pump  joint washer. 
7. Remove  the shim  washer  located  between  the front 
cover  and 
thc layshaft  front bearing. 
- STl234M 
16. Press in the oil feed  ring,  using 18G134 guide  and 
18G134DG adaptor. 
17. Fit the ball, spring  and plug.  When  fitted, the plug 
must  be flush  with, 
or not more  than 0,25 mm 
(0.010 in) below  the front cover rear face. 
18. Fit the oil pump  ring gear. 
ST1235M N 
Overhaul 
8. 
9. 
10. 
11. 
12. 
13. 
Remove  the pump  cover gasket  and oil pump 
drive. 
Withdraw  the 
oil pump ring gear. 
Remove  the oil feed  ring. 
Withdraw  the 
oil seal. 
Remove the plug and withdraw  the ball  and spring 
from  the relief  valve  housing. 
If  required,  drift 
off the extension  sleeve. Fit a 
repiacemenr  using iocrite 275 grade. 
Reassemble 
14. Press in the oil seal,  plain  face first,  using  186134 
guide  and 
186134DG adaptor. ST1236M 15. Align  the centre hole of three in the  oil feed  ring 
50 
with the oil delivery  hole in the  front  cover.  
						

							LT 95 FOUR SPEED GEARBOX (37( 
Fit cover  assembly to gearbox 
19. Position  the layshaft  bearing shim washer. 
20.  Position 
the front  cover  assembly  and loosely  fit 
the  fixings. 
21. Fit  the  oil pump  drive gear to engage  the drive 
square 
in the  layshaft. 
22. 
Fit the  oil pump  cover and joint  washer  and fit the 
fixing  screws  and washers  and carefully  tighten to 
the  correct  torque. 
23. Fit the gauge R01005 to align  the primary  pinion 
with the bell housing. 
24. Visually  check that the front  cover  is concentric 
about  the primary  pinion. Adjust 
the front cover 
position  about its fixings  to suit. 
ST1237M 
25. When  satisfactory,  tighten the front  cover  fixings. 
26. 
Fit the  clutch  release  lever and spring  clip. 
27.  Fit the  slave  cylinder  push
-rod. 
28. 
Fit the  release  bearing  assembly. 
29.  Fit the  retainer  staple 
to the clutch release  bearing 
assembly  and lever. 
REMOVE AND  OVERHAUL  BEARING PLATE 
ASSE MB LY 
1. Remove the bell  housing and position  the gearbox 
with the front  end uppermost. 
2.  Remove  the oil pump  gears cover  and joint  washer. 
3. Withdraw  the oil pump drive gear. 
4. Temporarily  remove the four  fixing  studs from the 
gearbox 
front face. 
5. Ease  the bearing  piate away  from the gearbox. 
6.  Withdraw  the two  dowel  sleeves  which locate the 
bearing  plate. 
7. Withdraw  the bearing  plate assembly  complete 
with primary pinion and layshaft. 
8. Withdraw  the joint  washer. 
9. Withdraw  the layshaft. 
- ST1238M 
Assemble  bearing plate assembly 
NOTE: To replace  a bearing  plate, a bearing plate and 
gearbox  casing mated  assembly  must be fitted. 
10. Locate the cone into the third/fourth-speed 
11. Lubricate  the oil tube,  using  clean gearbox  oil. 
12. Position  the joint  washer. 
13. Engage  the layshaft with the primary  pinion and 
front  bearing  outer member. 
14. 
Fit the  bearing  plate and layshaft. 
15. Align  the bearing  plate with the gearbox  casing and 
slide home  the dowel  sleeves. 
16.  Refit  the studs. 
Smcar Loctite  Studlock  grade 
CVX,  on 
the two upper  studs securing  threads 
before  fitting. 
synchromesh 
unit. 
17. Fit the oil pump  drive gear. 
18.  Using  a new  joint  washer 
fit the oil pump  gear 
19. 
Fit the  bell  housing. 
cover. 
51  
						

							LT 95 FOUR SPEED GEARBOX 
REMOVE AND OVERHAUL  PRIMARY PINION 
1. Remove the bell  housing. 
2. Remove  the front  cover  and oil pump  assembly. 
3. Remove  the bearing  plate assembly. 
4. Remove  the circlip. 
5. Lift  off the  shim  washer. 
6. Press  out the primary  pinion. 
ST 1 240M 
7. Withdraw the bearing retaining  plates and serrated 
8. Press  out the primary  pinion bearing. 
bolts.  ~  ~~~  ~  ~~  ~ 
Assemble 
primary pinion 
9. Check that the orifice drilkd in the oil tube  is clear. 
10. During  refitting,  take care to avoid  damage  to the 
oil  tube.  Rotate  the shaft 
in the  bearing to ensure 
that  the oil tube  is straight. 
11. Support  the bearing  plate using  suitable  wooden 
blocks.  Position  the blocks  across the bearing 
housing  aperture  to act 
as assembly stops. 
12. Press in the  bearing  until flush  with the bearing 
plate. 
13. Press in the  primary  pinion. Check that the bearing 
remains  flush 
with the bearing  plate. 
14. Fit the retaining  plates and serrated  bolts. 
15. Fit the shim  washer  and circlip. 
16. Measure  the clearance  between the circlip  and the 
shim  washer.  There must 
be a clearance  of 
0,05 mm (0.002 in) maximum. 
17. If required,  adjust the clearance  by fitting a 
replacement  shim washer.  Shim range  is 
2,O to , 
2,15 mm (0.079 to 0.085 in) in 0,05 mm (0.002 in) 
stages. 
18. Fit  the  bearing  plate assembly. 
19. Fit the front  cover  and oil pump  assembly. 
20. Fit the bell  housing. 
52  
						

							LT 95 FOUR SPEED GEARBOX 1371 
- -. ..._ __ ,.~ ., .1-. REMOVE AND OVERHAUL THE MAINSHAFT 
.....,. . ., ASSEMBLY .. . . ..L ...,. ., .. ... ..-. . 
Special  tool: 
1861388 -extractor  for mainshaft  spacer and gear 
1. Remove  the bell  housing. 
2. Rcmove  the front  bearing  plate. 
3. Remove  the main  gearchangc sclectors. 
4. Removc  the mainshaft  rear bearing  housing  and 
5. Remove  the bottom  cover from the transfer 
roller 
bearing. 
gearbox. 
NOTE: At  this  stage  in the  dismantling,  on early 
gearboxes  only, it is  necessary  to remove  the transfer  top 
cover  selector  finger and shaft.  On later  gearboxes  the 
cross
-shaft  is machined  to enable  the spacer to be 
completely  withdrawn.  Also the main  shaft  spacer  and 
transfer  gear are secured 
by Loctite 275 to the  main 
shaft. 
6. Remove  the snap-ring,  shim  washer  and mainshaft 
transfer  gear, using special  tool 
18G1388. 
7. Fit extractor 1861388 to transfer  gear spacer. 
8. Withdraw  the spacer  along the mainshaft  until the 
larger  diameter 
on the spacer  reaches the transfer 
gear  lever  cross
-shaft. 
9. Withdraw  the spacer  through thc machined 
10. When the spacer is free on the mainshaft removc 
scollop. 
the extractor. 
1 I. Withdraw  the mainshaft  assembly, allowing the 
first
-speed  gear to remain  behind to avoid  fouling 
on 
thc casing. 
12. Lift  out the first-speed  gear. 
13. Refit thc first-speed  gear, scalloped  thrust washer, 
thrust  needle  bearing  and stepped  thrust washer, 
stepped  face outwards. 
14. Withdraw  the mainshaft  spacer. 
. 4. .. . I.! .;:: 
ST1246M 
53  
						

							LT 95 FOUR SPEED GEARBOX 
Overhaul  mainshaft assembly 
Dismantle 
15. Withdraw thc first-speed  gear, thrust  washers  and 
roller  bearings  from the rear 
of the shaft. 
16. Remove  the snap-ring  and shim  washer  from thc 
front of the shaft. 
17. Lift off the third/fourth gears  synchromesh 
assembly. 
18. Withdraw  the third  and second-speed  gears and the 
associated  thrust washers  and 
needle-rollcr 
bearings. 
19. Dismantle  the third/fourth gears synchromesh 
assembly,  first pushing  down the sliding  blocks 
to 
free the synchromesh  balls from  the retaining 
groove 
in the  outer  member. 
29 - 
21 
Assemble 
22. Replacement  thrust washers  and roller  bcarings 
must  not be degreased. 
23. Lubricate  all items  before  assembly, iising clcan 
main  gearbox  oil. 
24. Fit the  oil seal  to the mainshaft  front end. 
Assemble synchromesh units 
25. Fit together  the thirdfourth gcar synchromesh 
outer  and inner  members,  outer member  coned 
face  toward  inner member  plain face. 
26. Fit the  sliding  blocks,  radius face  outward. 
27. Locate the springs  through  the sliding  blocks into 
the  housing  bores in the  inner  member. 
28. Position  the balls on thc spring  ends; press home  in 
sequence  and retain  by hand. 
29. Lift  the outer  member  to retain  the balls.  Continue 
lifting  until 
the balls spring  home into the annular 
30. Assemble  the first/second gear synchromesh  unit in 
the  manner 
dcscribed for third/fourth gear  unit. Fit 
the outer  member  coned face toward  the front  end 
of the mainshaft. 
~-~ groove in the outer  member. 4.L. 
Assemble mainshaft front  end 
31. Fit a synchromesh  cone to the firstkcond gcar 
synchromesh  outer member. 
32. Position  a chamfered  thrust washer,  a thrust  needle 
bearing  and a scalloped  thrust washer  on the 
mainshaft. 
33. Fit a radial  needle  bearing  and the second-speed 
gear. 
ST1247M 
20. Dismantle  the firsthecond gears synchromesh 
assembly 
in a  similar  manner,  particularly  noting 
their  position 
for refitting. 
21. Withdraw  the oil scal from  the Sore in the 
mainshaft  front end. 
-2w ST1249M 
ST 1248M 
54  
						

							.,.. ,.  .. ., -... . r ,: 5 -.: : . . .: . ,. .. 
LT95 FOUR SPEED GEARBOX 137 
34. Fit a scalloped  thrust washer,  a thrust  needle 
bearing  and 
a further scalloped  thrust washer. 
35. 
Fit a radial  needle  bearing  and the third-specd 
gear. 
36. 
Fit a  scalloped  thrust washer,  a thrust needle 
bearing  and a further  scalloped  thrust washer. 
37. Position  a synchromesh  cone onto the third-speed 
gear. 
38. 
Fit the synchromesh  unit, coned  face to rear. 
Set  end-float  of gears 
39.  Position  the mainshaft asscmbly vertical,  front end 
40.  Apply  a light  loading 
on the gears to remove 
41.  Position  the snap
-ring in the mainshaft  groove. 
42.  Measure  the distance  between the snap
-ring  lower 
edge  and the synchromesh  unit inner  member. 
43.  Select  a shim  to reduce  the measured  clearance  to 
0,025  to 0,150 
mm (0.001 to 0.006  in) when  fitted. 
44. Shim range  is 1,85 to 2,45 mm (0.073 to 0.096 in) 
in 0,15 mm (0.006 in) increments. 
45.  Fit the  selected  shim washer  and the snap
-ring. 
uppermost. 
end
-float. 
Assemble  mainshaft  rear end 
46. Fit a synchromesh  cone to the first/second gear 
synchromesh  outer member. 
47.  Position  a 
chamfercd thrust washer,  a thrust  needle 
bearing  and 
a scallopcd thrust washcr  on the 
mainshaft. 
48. 
Fit the  first-speed  gear and bearing. 
49. Fit a scalloped  thrust washer,  a thrust  needle 
bearing  and the stepped  thrust washcr,  stcppcd 
face  outwards. 
50. 
The mainshaft  spacer, transfer  gear, shim washer 
and  snap
-ring  are fitted  during  mainshaft  refitting. 
ST1253M 
Assemble mainshaft  assembly to gearbox 
51.  Position  the gearbox  with the R.H. side 
rfownwar& to .id refittifin 
52. Remove  the gearbox  side cover. 
53.  Temporarily  move the first
-speed  gear toward  the 
rear  of the  shaft. 
54.  Offer  the assembled  mainshaft 
to the gearbox  and 
manoeuvre  the first
-speed  gear past the reverse 
idler  gear. 
6 
55  
						

							137 I LT 95 FOUR SPEED GEARBOX 
55. Engage the shaft into the main  bearing. 
56. Engage  the first/second gear synchromesh  outer 
member  and the reverse  idler gear. 
57.  Push  the mainshaft 
home enough to allow  the 
mainshaft  spacer to 
be locatcd on the  rear  end, 
with 
the spacer  larger diameter  forward of the 
transfer  gear lever  cross
-shaft. 
60 
58. Re-position  the first-speed  gear, thrust  washers 
and  thrust  needle  bearing  correctly on the 
mainshaft. 
59. Push the mainshaft  fully home,  ensuring  that the 
thrust washers  and needle  bearing  remain correctly 
located  against the first
-speed  gear. 
60.  Move  the mainshaft  spacer along 
thc shaft, and 
into 
the oil seal,  to abut  the main  bearing. 
61. Temporarily fit the mainshaft  transfer gear. 
62.  Position 
thc snap-ring in the  groove in the 
mainshaft. 
63. Hold the  mainshaft  fully to the  rear  and measure 
the  clearance  between the snap
-ring  and the 
transfer  gear. 
64. Select a shim  washer to allow  0,050 mm (0.002 in) 
maximum  clearance between 
the snap-ring and 
transfer  gear when  fitted.  Shim range 
1,8 to 
2,O mm (0.071  to 0,079 in) in 0,OS mm (0.002 in) 
increments.  ~~ 
65. Temporarily 
remove the snap-ring  and the fl 
66. Slide  back the mainshaft  spacer as far  as the 
transfer  gear lever  cross
-shaft will allow. 
67. Apply  a thin coating  of Loctite  275 grade  to the 
exposed  area 
of the mainshaft. 
68. Push  home  the mainshaft  spacer. 
69. Fit the mainshaft  transfer gear. 
70. 
Fit the previously  selected shim washer  and secure 
with  the snap
-ring. 
71. 
Fit the  bottom  cover to the transfer  box using a 
new  joint  washer  and evenly  tighten  the fourteen 
retaining  bolts 
to the correct  torque. 
72. 
Fit the  mainshaft  rear bearing  housing  and roller 
bearing. 
73. Assemble  the main  gearchange  selectors to the 
gearbox. 
74. 
Fit the  front  bearing  plate. 
75. 
Fit the  bell  housing. 
....+I mainshaft  transfer gear. e;v 
REMOVE  AND OVERHAUL LAYSHAFT BEARINGS 
Special  tools: 
R01004 - extractor  mainshaft  spacer 
18G284 - extractor  and 18G284AR - adaptor, 
extractor  layshaft rear bearing  outer member 
18G47 - Press and 1SG47BA - Collars, extractor  for 
layshaft  bearing inner members 
1. Remove  the bell  housing. 
2. Remove the front  cover  and oil pump  assembly. 
3. Remove  the main  gears  selectors. 
4. Remove  the front  bearing  plate assembly. 
5. Remove  the mainshaft  assembly. 
6. Press out the layshaft  front bearing  outer member 
from 
the front  bearing  plate. 
gy.. %; ;r 
3 ST 1256M 
56