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 components  on to the mainshaft. 
Assemble  1st gear 
on to the  bush  and using  a 
suitable  straight edge 
or flat plate  (the oil pump 
back  plate 
is ideal)  check  the end  float of 1st gear 
on the bush  as shown. The tolerance  is identical to 
.. .. 
I. 
S7 
3rd  and  2nd  gear  end floats. 
-1 540M 
lsthd synchromesh end float 
6. Next fit the 1st gear  baulk  ring, 1st gear bush  and 
gear,  original  selective  washer, dummy bearing 
LST 101 and circlip  onto the shaft,  then check  the 
end 
float as  shown.  Choose  a suitable selcctivc 
shim  washer to obtain  the correct  tolerance  which 
is  identical  with 
3rd/4th synchromesh, i.e. 
minimum to 0,075 mm (.U03 in). 
.. . .. .. .. . 
STl353M 
.6 
-6 
5th gear synchro end float 
8. Fit the 5th  gear  synchromesh  backing plate, seal 
collar,  original  selective  shim washer  and circlip. 
Then check  the clearance  as shown;  select a 
suitable  shim washer  to minimise  the clearance. 
I his adjustment  is identical to the lst/2nd and 
3rd/4th synchromesh  units. 
With  all 
thc mainshaft  adjustments  correct, remove 
the  5th  gear  componcnts  ready 
for assembly. 
?. 
5th gear selector fork and bracket assembly 
1. Remove slipper pads from  selector  fork and check 
2. If necessary,  remove circlips and remove  selector 
3. Clean all componcnts  and refit  in reverse  order. 
for wear. 
fork  pivot  pins. 
77  
						

							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 washer and input 
shaft  bearing. 
If a measurcmcnt in excess  of 
0,075 
mm is  obtained  remove circlip and washer. 
4. 
Fit  layshaft  front bearing  track. 
5. Fit rear bearing  race to layshaft,  ensuring  the 
identification  numbers etc., 
of the bearing  are 
facing  forwards. 
NOTE: Inner tracks  are  offset  and  the  bearings 
must 
be fitted  with narrow shoulders together. 
Reverse  idler gear  assembly,  shaft and lever 
1 Secure  reverse  gear in vice and iemove circlip 
retaining  bearings 
2 
ST1357M STl359M 
2. Remove  upper thrust  washer,  two needle  roller 
3. Invert reverse  gear and remove  second circlip. 
bearings 
and lower  thrust  washer. 4. If necessary, - - IC~IIUVC spiit piin and withdraw siipper 
5. Press out reverse  lever cross  link operating  pin, if 
6. Clean all components and check for wear. 
7. Lubricate  needle roller bearings  and reassemble 
reverse  idler gear  assembly  and lever 
in reverse 
order.  pads 
and washer 
from reverse  gear lever. 
necessary. 
78 
3. Selcct  and measure  new washer to takc up the 
5. Fit new selective  washer and retain  with circlip. 
6. Recheck to ensure a running  clearance  of 
0,075 
mm is  obtained  between washer and bearing. 
8. Lubricate  mainshaft  pilot bcaring  and fit to input 
9. Fit 4th gear baulk  ring to input shaft. 
excessive 
running 
ciearance. 
7. Position front bearing  plate on suitable  stand. g-:: I .L t., ,, shaft.  
						

							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 
ST1361M 
Gearbox  case and reverse  shaft 
16. Fit new gasket  on front  bearing platc. 
17. Lower  gearbox  case over mainshaft/layshaft 
asscmblics  using guide  studs to locate  front bearing 
plate. 
18. Fit tube, Tool No. LST 1431-1  over  mainshaft and 
locate on rear bearing. 
19. Fit Tool No. 18G 1431  over  mainshaft  and locate 
on  other 
tool. 
20. With  assistance, to prevent  gearbox  and mainshaft 
rotation,  and using  above  tools, 
pull gearbox  to 
front  bearing  plate. 
12 
ST1358M 
13. Remove  the rear  bearing  circlip and dummy 
.. bearing. 
Reverse  gear 
14. Fit thrust washer to reverse  gear, chamfer  towards 
gear,  locate  gear in gearbox  case, and retain 
temporarily 
in position  with a screwdriver,  or 
similar  implement. 
1 .. 
19 
8 
. 
I J 
/I7 
@ 
ST1362M 
79  
						

							. 
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 location 
and 
fit reverse  shaft. 
26.  Invert  gearbox  and 
fit spacer to layshaft  front 
27. Using Tool Nos. LS’I‘ 550-1 and MS 550 locate 
bearing. 
layshaft 
front bearing  to final  position. 
27 
ST1364M 
28. Temporarily  remove layshaft  bearing spacer. 
29.  Refit  gcarbox  stand (manufactured  tool) 
to 
underside of gearbox and secure  with two bolts, 
nuts,  spring  and plain  washers.  Adjust bolt 
undes 
filter housing  as necessary. 
30. Secure  gearbox  stand in vice. 
31.  Check  that 
4th gear baulk ring and all other  baulk 
32. 
Fit layshaft  front bearing  spacer. 
33. 
Fit new  gasket to front  cover. 
34.  Tape  input shaft splines,  to prevent 
damagc to 
80 
rings  are free. 
front  cover  oil seal 
in next  operation.  35. 
Ensure 
oil pump  drive aligns with the square 
seating 
in the  layshaft  and fit front  cover to front 
bearing  plate and secure 
with seven  bolts and 
spring  washers. 
36.  Removc  tape from  input  shaft splincs. 
Reverse  lever, reverse shaft/bearing retaining  plate 
37. Fit reverse lever to reverse gear. 
38. Apply  Loctite  Stud and Bearing  Fit (270)  to pivot 
bolt  threads, 
fit bolt in gearbox  and locate in 
reverse  lever pivot  boss. 
39.  Position  reverse shaft, layshaft  bearing track 
retaining  plate and secure  top of plate  with 
two 
bolts and spring  washers. 
39 
40. Apply  Loctite  Stud and Bearing Fit (270)  to socket 
head  set screws  and secure  bottom  of retaining 
plate. 
5th gear,  layshaft and mainshaft 
41. Remove  nut from  layshaft  and remove  dummy 
42.  Fit 5th  gear  to layshaft  with large  boss to the  rear. 
43.  Rotate  layshaft  to give  access  to stake  slot. 
44. To facilitate  next operation,  lock gearbox  by 
45. Fit a new 5th gear  retaining  nut and  tighten to the 
46.  Stake  retaining 
nut collar into recess in layshaft. 
47.  Return 
1st and 4th synchros  to neutral. 
48. Fit mainshaft  rear bearing  circlip. 
49. Fit thrust washer. 
50. Lubricate  needle roller bearings  and fit to 
51. 
Fit 5th  gear  synchro  cone and synchro  hub 
52. Tape mainshaft splincs and fit ‘0’ ring to its seating 
53. 
Fit oil  seal  collar  and locate in peg on hub  backing 
54. Fit the washer  selected  during the 5th  gear  end 
55.  Remove  tape. 
spacer. 
engaging  1st and  4th gears. 
specified  torque. 
mainshaft  followed by spacer  and 
5th gear. 
assembly. 
on  mainshaft. 
plate. 
float  check  and retain 
with circlip.  
						

							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 to rail, align  for roll  pin. 
and 
rail. 
and  locate 
in reverse  cross-over lever. 
68. Locate  selector rail into 5th gear  selector fork and 
secure  with clevis  pin, washer,  and split  pin. 
69. Fit roll pin and  secure  selector rail and jaw. 
70. Push  reverse  sclector  rail through  gearbox scating 
and  locate 
in reverse  cross-over. Do not lighten 
lever  clamp  bolt. 
71. Fit jaw to rail  and  align  for roll  pin. 
72. Using a suitable  drift, fit roll pin to secure sclccror 
rail and jaw. 
NOTE: The  roll pin must  be inserted  sufficiently  to 
be  flush  with the underside  face 
of the selector.jaw. 
72 71 I 73 
ST 1367M 
82  
						

							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  gasket  to housing. 
104. Grease  bias springs. 
105. Carefully fit shims  and bias  springs,  followed  by 
spring 
housing and  secure  with four set screws, 
and  spring  washers. 
106. Remove  gearbox assembly from vice and detach 
-stand. 
Gearbox  extension  housing 
107. The special  nut retaining the 5th gcar to the 
layshaft  must be secured  in position,  by carefully 
forming 
the collar of the nut into  the layshaft 
slots,  as illustrated. 
108. Support  underside  of gearbox  with wooden  block. 
109. Lubricate oil seal protection  sleeve Tool No. LST 
102 and fit to oil seal  from  inside  extension 
housing. 
ilG. Fit new  gasket  to extension  housing. 
11 I. Carefully  manoeuvre  extension housing over 
mainshaft  and position  squarely 
on dowels. 
CAUTION: A round nose tool must  be used  for 
this  operation  to avoid  splitting  the collar 
of the 
nut. 
Also, the  5th laygear should  be supported by a 
wooden  block when the nut 
is being  deformed,  to 
prevent  damage 
to the bearings  adjacent  to the 
gear. 
112. Remove  oil seal  protection  sleeve. 
113. Secure extension  housing to gearbox with eight 
bolts,  spring  washers  and single 
nut. 
NOTE: Illustration  shows correct  bolt lengths  and 
their  locations  in extension  housing. 
60 
45 I /n 
ST1374M 40 ST1483M 
a4  
						

							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. 
. _. . 
:: .:, -.i 
... , ., ;.i ,;:,’;~ ”.. ... ,,.- . .I 
123 II 
115. Select  3rd gear. 
116.  Tighten 
stop screw  until it makes  contact  with 
3rd/4th selector rail. 
117. Turn back stop Screw one turn. Retighten 124. Refit mounting  to extension  housing and secure 
locknut.  with four bolts. 
118. Return  gear lever  to neutral. 
119. Slacken  locknut on 3rd/4th stop bolt inside bell 
housing. 
Gearbox  mounting 
ST1376M ‘ 
120. Unscrew stop bolt. 
121.  Select  4th gear 
and screw in stop  bolt until  contact 
is  made  with 
3rd/4th selector  shaft. 
122. Turn back stop bolt one turn  and rctighten 
locknut. 
Return  gear lever  to neutral. 
85  
						

							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 
Lr230R transfer  gearbox, it can be modified to suit 
both  the 
LT230R and LT230T gearboxes  by making  the 
modifications  shown by the  large  arrows. 
Y I 1 12.63 67.0 12.63 6x0) 1 0.56 6- 5 -4-3 165.1 
ARC WE,LD TO BS5135 
! 6.43 ! 
rl i 
I 5-52 - 13 9.7 
;r--...----, 
Material.  Steel plate BS 1449 Grade 4 or 14 
Holes  marked  thus * to be  drilled  to fit hoist being 
used. 
$ = MODIFICATION 
86