Land Rover Defender 90 110 Workshop Book 3 Rover

							LT 95 FOUR SPEED GEARBOX 
,:.:.:.. i.: *:, 1 ... ... ..,; 7. Extract the layshaft  rear bearing  outer member 
from  the gearbox  casing, extiaetor  186284 and 
adaptor 
18G284AR. 
12.  Press the rear  bearing  outer member  into the 
13. Enter the front  bearing  outer member  into the 
.. I. :..:! gearbox  casing. 
front  bcaring  plate. 
DO not fit fully in at this  stage. 
37 
. 
8. Withdraw  the bearing  inner members  from the 
layshaft.  Extractor  18647 press and 
18G47BA 
col tars. 
n 
ST 1258M 
Check bearing pre-load 
8. Repiacement bearings  inner and outer membcrs 
are supplied as matched  pairs and not as separate 
items. 
10.  The  replacement  bearings must not be degreased. 
Before  fitting, lubricate  with correct  grade gearbox 
oil. Refer to lubrication  chart. 
11. Press the bearing  inner members  onto thc layshaft. 
IJ ST1259M 
14. Remove  the primary  pinion from thc bearing  plate. 
15. Position  the layshaft in the  gearbox  casing. 
16. Temporarily  fit the  front  bearing  plate and joint 
washer. 
17.  Press 
in the front  bearing  outer member  until thcrc 
is 
no end-float  on the  layshaft  and  no cnd-load on 
the bcarings. 
18. On the bearing  outer member  position a shim 
washer 
of a thickncss suitable  to stand 0,25 mm 
(0.010 in) approximately  proud of the  front 
bearing  plate. This shim  thickness  may be 
subsequently  adjusted depending  on the  amount 
of 
bearing  pre-load it affords. 
19.  Temporarily  remove the oil pump  top cover  and 
withdraw  the pump  drive gear. 
20.  Temporarily  fit the  front  cover  and new  joint 
washer  to the  bearing  plate. Ensure  that the shim 
washer  remains 
in position. 
c /- 
57  
						

							37 
21. Measure the rolling  resistance  of the  layshaft,  using 
a  spring  balance  and a cord  coiled  around  the 
layshaft  larger diameter.  The rolling 
rcsistance 
must be 7 to 3,38 kg (6 to 7.5 Ibs). 
REMOVE AND  OVERHAUL  DIFFERENTIAL  LOCK 
ACTUATORASSEMBLY 
1.  Remove  the four  bolts  and  withdraw  the assembly 
from front output shaft  housing. 
2. Remove  the detent  spring and ball. 
LT 95 FOUR SPEED GEARBOX 
22. To adjust  the pre-load, fit a replacemcnt shim or 
suitable  thickness to the front  bearing  outer 
member.  Shim range  is from 
1,55 mm (0.059 in)  to 
2,510 mm (0.098  in) in 0,05 mm (0.002 in) 
increments. 
23. When  the pre-load  is satisfactory,  remove thc front 
cover  assembly. 
24. Remove  the front  bcaring  plate. 
25. Fit the  primary  pinion. 
26. Fit the oil pump cover and drive  gear. 
27. Fit the front  bearing  plate assembly. 
28.  Assemble  the selectors 
for the  main  gears. 
29. Fit the  front  cover  and oil pump  assembly. 
30. Fit the bell  housing. 
Dismantle  and overhaul  assembly 
3. Remove thc differential lock warning  switch and 
4. Drive out the retaining  pin. 
5. Remove the actuator  fixings. 
6. Withdraw  the actuator  and shaft. 
7. Withdraw  the 0 ring seal. 
8. Withdraw  the joint  washer. 
washers. 
9. Fit 
a new 0 ring  seal to actuator  shaft. 
10.  Coat  both sides  of the  joint  washer  with Hylomar 
11. Fit the actuator  and shaft  and secui-c to the 
12. Fit thc actuator  shaft retaining  pin. 
13. 
Fit the  diffcrential lock warning  switch and 
PL32M. 
housing. 
washers. 
Assemble to gearbox 
14. Fit  the ball and  detent  spring. 
15. Apply Hylomar PL32M jointing  compound to both 
16. Fit and secure  the assembly to the gearbox and 
sides ot a new  actuator  housing joint washer. 
evenly  tighten  the 
four retaining  bolts. 
58  
						

							LT 95 FOUR SPEED GEARBOX 
. 
37 
Renew 
L 
Renew 3. Start the engine  and move  the differential  lock 
4. Connect the elcctrical leads to the  actuator  switch. 
5. Screw in the switch, less shim  washers, until the 
vacuum 
control valve 
to the ‘up’  position. 
3. Engagc  reverse gear. 
4.  Connect 
the electrical  leads to the switch. 
5. Switch  the ignition ‘ON’. 
6. Screw in the  switch,  less shim  washers,  until the 
switch  contacts  are madc. 
7.  Screw  in a further  half turn. 
8. Mcasurc  the clearance  bctwcen the switch  lower 
face  and 
the gearbox. 
9. Select  shim washers to suit the clearance.  Shim 
thicknesses  are 
0,5 mm (0.020 in) and  0,127 mm 
(0.005 in). 
10. Fit the sclected shim washcr(s) and switch.  Tighten 
to  a torque  of 1,4  to 
2,0 kgf m (15 to 20 Ibl lt) (20 
to  27  Nm).  switch 
contacts 
are made. 
ST 1265M 
6. Screw in a further  half turn. 
7.  Measure  the clearance  between the switch  lower 
face  and the housing. 
8. Select  shim washers  to suit  the clearance.  Shim 
thicknesses  are 
0,5 mm (0.020 in) and  0,137 mm 
(0.005 in). 
9. Fit the  selected  shim washcr(s) and the switch. 
10. Re-position  control valve and stop  engine. 
59  
						

							El LT 95 FOUR SPEED GEARBOX 
RENEW REAR OUTPUT  SHAFT OIL SEAL 
Remove  Renew 
7. Press in the 
oil seal,  open  face first, until the seal 
plain  face just clears  the chamfer  on the  seal 
housing  bore. 
8. Fit the oil shield,  which must be a close fit on the 
speedometer  housing. 
9. Fit the  oil catcher,  applying  Bostik compoiind 771 
to seal the oil catcher against  the brake  back plate. 
10. Fit the transmission  brake drum complete with rear 
1. Disconnect  the  rear propeller shaft at the 
transmission  brake. 
\  
 ST1266M 
   % \, 
  
coupling flange. 
to the correct  torque. 
transmission  brake. 
11. Fit the  oil seal washer and locking  nut and  tighten 
12. Connect  the rear  propeller  shaft to the 
RENEW FRONT OUTPUT SHAFT OIL SEAL 
2. Remove the locking nut, washer  and the felt  oil Remove seal. 
3. Withdraw the transmission  brake drum complete 
with  rear coupling  flange. 
4. Remove the oil catcher. 
5. Prise off the  oil shield. 
6. Withdraw  the oil seal. 
1. D~~~~~~~~~ the front propeller shaft. 
2. Remove the coupling flangc locknut  and washer. 
3. Withdraw  the coupling  flange complete  with 
4. Withdraw the oil seal. 
mudshicld. 
I ST1267M 
STl268M 
Renew 
5. Fit thc oil 
seal,  lip side  Icading. 
6. Fit the flange  coupling  with mudshield. 
7. Secure  the flange  with locknut  and washer  and 
tighten 
to the  correct  torque. 
8. Connect  the propeller  shaft. 
/-:. 
$x ,; 
60  
						

							LT85 FIVE SPEED GEARBOX El 
REMOVE LTWLT230T MAIN GEARBOX AND Cradle for removing gearbox 
The gearbox  should be removed  from underneath  the 
vehicle,  using a hydraulic  hoist, as illustrated; 
a cradle 
for  locating  the gearbox  on 
to thc hoist can be 
manufactured to the drawing below. If a similar  cradle 
was 
made for the  LT77  gearbox, it can be  modified  to 
suit  both 
the Ll77 and LT85 gearboxes by making  the 
modifications  shown by the  large  arrows. 
Manufacture  a cradle 
to the dimensions  given in the 
drawing and attach it to a transmission  hoist. To 
achieve balance of the transmission unit when mounted 
on the transmission  hoist, it is essential that point A is 
situated  over 
thc centre of thc lifting hoist ram. Drill 
fixing  holes 
R to suit  hoist  table.  Secure  the 
transmission  unit to the  lifting  bracket 
at point C, by 
mcans of the lower bolts retaining the transfer  gearbox 
rear cover. 
1 TRANSFER BOX 
* Refer to the  Removal  instructions  for the  LT77 
gearbox  page 
1. The method for removing the LT8Y 
LT230T gearbox  assembly  is similar,  except for the 
following. 
1. It is  not  necessary  to remove  the engine fan cowl. 
2. Remove  the air cleaner. 
3. Remove thc highhow selector housing  from the 
4. Use the cradle  and hydraulic  hoist already 
transfer 
box. 
described, 
to remove  the gearbox. 
NOTE: It may be  necessary  to remove  the 
transmission  brake 
drum to allow removal of the ST1547M 
8.75 gearbox assembly. 
1.0 x 1.0 x 0.13 -* 230x250~30 $0.19  . 5.0 
1 
f 0.25 
3.0 76 .O 
508.0 
MATERIAL  AND WELDING SPEClFlCATlON AVANT 
VORDER LT85 .. . Steel Plate BS 1449 (Grade 4 or 14) ANTERIORE .. .. 102.0 Tu be BS 4848  (Part 2) Arc Welding BS 5135 e = MODIFICATION 
ST 538M 
61  
						

							)371 LT85 FIVE SPEED GEARBOX 
OVERHAUL LT85 FIVE SPEED GEARBOX 
-Ninety and One  Ten V8 models 
Service  Tools: 
18G 1294 -Guide studs 
18G 1400 -Two legged  puller 
1% 1431 - Replacer,  mainshaft  bearings 
MS 284 -Slide hammer 
MS 550 - Driver handle 
LST 
101 -Gauge,  first gear  end float 
LST 
102 - Remover-Replacer,  mainshaft  rear oil seal 
LST 284-1 - Adaptor-Remover,  reverse idler shaft 
LST 
550- I - Adaptor-Remover-Replacer,  layshaft 
front  bearing  roller 
LST 
550-2 - Adaptor-Remover-Replacer,  layshaft rear 
bearing  outer track 
LST 
550-3 - Adaptor-Remover-Replacer,  mainshaft 
front  and rear  bearing 
LST 
1431-1 - Remover-Replacer,  front plate and 
mainshaft 
In addition to the above Service Tools, the following 
five  items  should  be manufactured 
locally to facilitate 
dismantling  and reassembly 
of the gearbox. 
ST1369M 
ST1476M 
Spacer  for retaining  layshaft rear bearing  Selector 
detent spring  retaining  tool and spaccrs. 
A - Spacers can be madc up from washers 
I 
ST1371M ST1475M 
Spacers  for retaining  front bearing  plate. Two required. 
A -This dimension must be more  than 12 mm. Gauge  for reverse  cross-over lever  adjustment. 
62  
						

							LT85 FIVE SPEED GEARBOX 137 
1 ~ . .. , ... 
ST1321M 
Stand for securing the gearbox in a vice 
A. 11 mm diameter 
holes 
R. Make from 50 mm x 6 mm stcel angle 
C. Make from 6 mm steel plate 
D. 10 mm diameter  bolt with  hexagonal  head 
E. 10” nuts 
MATERIAI, AND WELDING  SPECIFICATION 
Steel Plate BS 1449 (Grade 4 or 14) 
Arc Welding BS 5135 
63  
						

							LT85 FIVE SPEED  GEARBOX 
GEAR CASINGS 
Bell housing  and clutch  release  assembly 1. 
2. 
3. 
3. 
5. 
6. 
7. 
. 
Oil pump assembly 
Front  bearing  plate 
Main  gear case 
Oil filter  assembly 
Gear  change  lever assembly 
Extension  housing 
m 
64  
						

							I . .. 
... .. 
.I- ., 
						

							LT85 FIVE SPEED GEARBOX 
A-- 
 L- 
66