Land Rover 90 110 Workshop Rover Manual
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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
LT85 FIVE SPEED GEARBOX I 1 I l. GEARBOX DATA - 37 Mainshaft first speed gear running clearance Mainshaft third spccd gcar running clearance Mainshaft fifth speed gear running clearancc Input shaft bearing running clcarance 0,075 mm maximum 0,075 mm maximum 0,075 mm maximum 0,075 mm maximum DISMANTLING Bias spring housing and gear lever 1. Ensurc gearbox oil has bcen completely drained. 2. Position gearbox on bench and support with 3. Remove four bolts and detach L.H. gearbox 4. Remove extension housing and gasket. 5. Fit manufactured stand to gearbox and secure with two bolts, nuts, spring and plain washers. Adjust bolt under filter housing as necessary. suitable wooden block. mounting bracket. c LI ST1322M 6. With assistance, fit gearbox and stand into a suitable vice and firmly sccurc. 7. Removc six bolts and washers and lift bcll housing, complctc with clutch release lever, sleeve and thrust bearing, lrom gearbox. 8. Remove bell housing gasket. 9. Fit two bell housing fixing bolts, with spacers to front bearing plate. ST1323M 10. Remove four bolts and spring washers and lift bias spring housing from gearbox. 11. Remove bias springs and shims. Care should be taken when removing lower shims to avoid them slipping under gear lever pivot bar and into gearbox. 12. Removc bias spring housing gasket. 13. Remove gear lever, complctc with gaitcr and nylon cup. ST 12 13 1318M 10 11 Gearbox top cover 14. Remove reverse light switch, if fitted. 15. Remove breather pipe banjo union fixing bolt. 16. Remove eight bolts and spring washers and lift top 17. Remove detent springs. 18. Remove top cover gasket. cover and breather pipes from gearbox. 67
17 LT85 FIVE SPEED GEARBOX Selector rails and forks 19. Using a suitable magnet withdraw the selector rail detent balls from drillings in gearbox. If detent balls arc tight leave operation until after selector rails have been withdrawn, when the detcnt balls can be pushed down into the selector rail borc, then removed. 20. Release reverse gate spring from knock-over lever and remove from reverse gear rail. 21. Raise knock-over lever and tap down reverse jaw roll -pin until jaw is free on rail. 22. Remove clamp bolt from reverse cross-over lever and withdraw reverse selector rail and jaw from gearbox. 23. Remove split pin washer and clevis pin securing 5th gear selector rail to selector fork and bracket asscmbiy. 24. Push selector rail forwards and tap down 5th gear jaw roll pin until jaw is free on rail. 25. Withdraw 5th gear selector rail and jaw from gearbox. 26. Remove clamp bolt from 3rdi4th selector fork and move selector rail forward. 20 I I . ST1324M 68