Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							J 
Workshop Bulletin 
band  Rover 
Range  Rover 
- , .: -*a .I ATTENTION  SERVICE MANAGER 
LAND ROVER 
1 ,”, i 
LT85 LIGHTWEIGHT 
D lVID E D -CASE GEARBOX 
DECEMBER 1987 
BULLETIN  No. SLR 621 EN WB 3 
Further  supplies of this Bulletin  can be obtained, free of charge, from: 
Land  Rover  Merchandising  Service, 
P.O. Box 534, Erdington,  Birmingham B24 OQS 
. -3 SERVICE Land Rover  Service  Division  
						

							37 
INTRODUCTION 
TRANSMISSION 
This Workshop  Bulletin is a supplement  to the 
current 
Land Rover  Workshop  Manual Publication 
SLR  621 
EN WM and  covers  the introduction  and 
overhaul 
ofthe LT  85  light  weight  divided - case 
gearbox.This unit replaces  the earlier  heavy duty LT 
85  gearbox  fitted to the  basic 
V8 engined  Land 
Rover  90 and 
110 models.  The heavy  duty version  is 
still  being  used 
for certain  non - standard 
applications. 
The  new  gearbox,  which 
is interchangeable  with the 
heavy  duty version,  can 
be recognised  by the  prefix 
22C before  the serial  number.  The gearbox  was first 
fitted  from the following  vehicle numbers: 
Land  Rover 
90 V8. VIN SALLD VBV 7AA 299109. 
Gearbox  number 22C 00070. 
Land  Rover 
110 V8. VIN SALLD HAV 8BA 298614. 
Gearbox  number 22C 00061. 
The  individual  gears and shafts  are not,  however, 
interchangable  between the 
two gearboxes. 
GEARBOX  DATA 
Ratios:  as heavy  duty version. 
Lubrication: 
as heavy  duty version. 
Torque  figures:  as heavy  duty gearbox  where 
applicable  with the exception 
of 
the following: 
Divided 
case retaining  bolts M8- 7off (5 bolts  and 
two bolts and nuts)  22- 28 Nm (16-21 Ibs.ft.) 
Maintenance: Oil check  and top-up and  drain  and 
renew 
oil are  at the  same  mileage 
intervals  but the drain  and 
refil 
method  differs from the heavy  duty 
gearbox, 
as follows: 
1. Immediately  after a run,  when  the oil is warm, 
park  the vehicle  on level  ground  and 
disconnect  the battery.  Drain
-off the oil into  a 
container 
by removing  the drain  plug 
anti
-clockwise  from beneath  the gearbox 
casing  using 
a 12,7mm (1/2in) square  socket 
drive.When all the oil is drained,  clean and 
refit  the drain  plug and tighten  to the  correct 
torque.  2. 
Remove  the square  headed 
oil IeveVfiller plug 
from  the left
-hand  side of the gearbox  and 
inject 
oil of the  correct  grade until the oil is 
level  with the 
filler hole.  Clean  and fit the 
level/filler plug and  tighten  to the  correct 
torque.  wipe away  any surplus 
oil and 
reconnect  the battery. 
GEARBOX  AND 
TRANSFER BOX REMOVAL 
This operation  is the  same  as  that  described  in 
Supplement 
LSM 25WS and  the current  Land Rover 
Workshop  Manual Publication  SLR 621 EN WM for 
the heavy  duty LT 85 gearbox. 
In  the  interests 
of saftey,  it is essential  that the 
locally  manufactured  cradle 
is used with the 
hydraulic  ramp. Before  fitting the cradle  the 
gearbox 
filler/level plug  must  be removed  and a 
suitable  blank fitted. 
i- . 
Iv ?c 
2  
						

							TRANSMISSION 
.1 OVERHAUL LT85 LIGHT WEIGHT DIVIDED CASE 
GEARBOX. ._> .. 
37 
Service Tools 
L 
18C 284  Impulse extractor. 
LST 284-1 
LST 101 
LST 102 
MS 47 Hand press. 
Reverse 
idler shaft  remover 
adaptor. 
Gauge  first gear  end
-float. 
Mainshaft 
oil seal  remover, 
replacer. 
1 mm 
With  the exception of MS 47 the  above  are existing ST1369M 
tools used  on the  heavy  duty LT 85 integral  case 
gearbox.  Selector detent spring retaining  tool and spacers. 
Special 
sockets and  spanners. 
-------------pi I 41 socket - Layshaft  fifth gear  retaining  nut. 
5mm Allan key - Reverse shaft retaining  plate 7mm I I------- 19r 4 _LpJ$--- 
If 
Locally manufactured  tools. 
In addition to the  above service tools,the following 
dismantling  and assembly 
of the gearbox.  These 
tools  are the same  as
-for the  heavy  duty gearbox 
except  the stand  to which  a 
smalf modification  is 
necessary. 
-Il 8 mm !- 
LL 
A L I tools can  be locally  manufactured to assist the ~2-2.5& 3m 
f 
,1 
7-1 
ST1371M 
ST1476M 
Spacer for retaining  layshaft rear bearing.  Gauge 
for reverse 
cross-over  lever adjustment. 
Continued 
3  
						

							137 I TRANSMISSION 
STZOOaVl 
Stand for securing the gearbox  in a vice 
A. Ilmm diameter  holes. 
B. 
C. 
D. 
E. 1Omm nuts. 
Make 
from 
50 x 6mm steel angle. 
Make  from 
6mm steel plate. 
10mm diameter  stud 70mm long with 
25 of thread for adjustment. 
Note: 
Item D is where  the modification  to the 
original  stand 
is necessary. 
Material  and welding  specification 
Steel  plate 
BS 1449 Grade 4 or 14 
Arc  welding 
BS 5135. 
4  
						

							TRANSMISSION 
1.. ... I. .,.. I.. ..... .,I .,!.,: . . . .. ..... 
37 
5 
L  
						

							37 
. 
TRANSMISSION 
6  
						

							.,__ .I . . .,. . ... .. .# ., 
I .. .. -.. . .. -. .. . ,. . 
KEY TO GEARS AND SHAFTS 
MAINSHACT ASSEMBLY  A. 
1. 
2. 
3. 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
12. 
13. 
14. 
15. 
16. 
17. 
18. 
19. 
20. 
21. 
22. 
23. 
24. 25. 26. 
27. 
28. 
29. 
30. 
31. 
32. 33. 
34. 
35. 
36. 
37. 
v 38. 
Mainshaft. 
Circlip. 
Selective  washer. 
4th  gear  baulk ring. 
3rd14th gear synchromesh  sleeve. 
3rd/4th gear synchromesh hub. 
3rd gear  baulk ring. 
Spacer. 
3rd  gear. 
Needle  roller bearing. 
2nd  gear. 
2nd  gear 
baulk ring. 
Needle  roller bearing. 
Spacer. 
1 st/2nd synchromesh  sleeve and reverse  gear. 
IsW2nd gear synchromesh hub. 
1st gear  baulk ring. 
1st gear. 
Spacer. 
Needle  roller bearing. 
1st gear bush. 
Selective  washer. 
Ball  bearing. 
Snap 
ring. 
Circlip. 
Washer. 
Needle  roller bearing. 
S pacer. 
5th  gear. 
5th gear baulk ring. 
5th gear  synchromesh. 
5th.gear synchromesh  sleeve. 
5th  gear Synchromesh  plate. 
Dowel  retaining  plate. 
0 ring seal. 
Sleeve 
Selective Circlip. 
INPUT SHAm ASSEMBLY B. 
1. 
2. Circlip. 
3. Selective  washer 
4.  Snap 
ring. 
5. Ball bearing. 
6. Needle  roller bearing. 
Input shaft and 4th gear 
MYSHAFT ASSEMBLY C. 
1. 
2. 
3. 
4. 
5. 
6. 
7. 
8. 
9.  10. 
11. 
12. 
13. 
14. 
Layshaft 
Spacer.  Roller bearing. Roller  bearing  track. 
4th  gear. 
3rd  gear. 
2nd  gear. 
Reverse  gear. 
1 st gear. 
Inner  ball bearing  race. 
Bearing  track. 
Outer  ball bearing  race. 
5th  gear. 
5th  gear  retaining 
nut. 
REVERSE  SHAFT ASSEMBLY D 
1. 
2. 
3. 
4.  5. 
6. 
7. 
8. 
Reverse  idler gear  shaft 
Wire  circlip. 
Reverse  idler gear. 
Washer.  Needle  roller bearing. 
Wash  er. 
Wire  circlip. 
Thrust  washer.  
						

							E1 TRANSMISSION 
N 
8  
						

							DISMANTLE 
TRANSMISSION 
1. Ensure that the gearbox oil has been  drained. 
2. Position  gearbox  on a bench  and support  with 
a  suitable  block 
of timber. 
3. Remove  the four  bolts  and detach  the L.H. 
mounting  bracket. 
4. Remove the eight  bolts,  four forward  facing 
and  four 
reanvard facing  and withdraw  the 
extension  housing and gasket. 
37 
5. Fit the  locally  manufactured  stand to the 
. gearbox  and secure  with two bolts, nuts, 
spring 
and plain  washers. 
6. Adjust  the stud  under  the gearbox  case as 
necessary 
so that  it just  contacts  the case  to 
provide  support. 
7. Secure the gearbox  and stand  in a vice. 
8. Remove  the six bolts and withdraw  the bell 
housing complete  with clutch  release  lever, 
sleeve  and thrust  bearing  from the gearbox. 
9. Remove  the bell housing  gasket. 
Bias spring housing  and gear  iever. 
1. Remove  the four  bolts  and lift the  bias  spring 
housing  from gearbox. 
2. Remove  the bias  springs  and shims.  Take care 
not  to allow  the 
lower shims  to slip under the 
gear  lever  pivot  bar into  the gearbox. 
3. Remove  the bias  spring  housing  gasket. 
4. Remove  the gear  lever  complete  with gaiter 
and  nylon  cup. 
9  
						

							(37 I TRANSMISSION 
Gearbox top cover. 
1. Remove the reverse  light switch, if fitted. 
2. Remove  breather pipe banjo union fixing bolt. 
3. Remove  the eight bolts and lift the top cover 
and  breather 
pipes from  gearbox  whilst taking 
care  not to allow  the detent  springs  to fall  into 
the  gearbox. 
4. Remove  the detent  springs. 
5. Remove  the top  cover  gasket. 
. 
Selector  rails and forks. 
1.  Using  a magnet,  withdraw  the 
selector rail 
detent  balls from  drillings  in gearbox. 
If the 
balls  are tight  leave  until the selector  rails have 
been  removed. 
2. 
Release reverse  gate spring  from the 
knock
-over  lever  and remove  from reverse 
gear  rail. 
3. Raise  the knock-over  lever  and tap down  the 
reverse  jaw 
roll pin until the jaw is free on the 
rail. 
4. Remove  the clamp  bolt from  the reverse  gear 
cross
-over  lever, slide the reverse  selector  rail 
out  from  the gearbox 
and remove  the jaw. 
5. Remove  the split  pin, washer,  and clevis pin 
securing  the fifth
-gear  selector fork to the  fifth 
gear  rail. 
6. Push  the selector  rail forwards  and tap down 
the  fifth
-gear  jaw roll pin until  the jaw is free 
on the  rail. 
7. Withdraw  the fifth-gear  selector  rail and  jaw 
from  the gearbox. 
8. Remove  the clamp  bolt from  the third/fourth 
selector fork and move  the selector  rail 
forward. 
9. Tap-down the thirdjfourth jaw roll pin until  jaw 
is free on the  selector  rail. 
10. Withdraw  the thirdlfourth selector rail and  jaw. 
11. Remove  the interlock  from the thirdjfourth 
selector rail. 
12.  Tap
-down  the first/second jaw roll pin until  the 
jaw  is free  on the  selector  rail. 
13. Remove  the clamp  bolt from  the firstisecond 
selector 
fork and  withdraw  the firstisecond 
selector rail and  jaw. 
14. Remove  the interlock  from the firstisecond 
selector  rail. 
15. Lift the  reverse  cross-over lever from the 
gearbox. 
16, Remove  the first/second and third/fourth 
selector forks. 
17.  Remove  the interlock  plungers,  and the detent 
balls, 
if the  latter  were  not removed  in 
instruction 
1, F- e:! 
10