Defender (1993+). Manual — part 50

LT77S MANUAL GEARBOX

DATA
Reverse lever and slipper pad clearance . . . . . . . .

0,725 mm

Reverse gear plunger operating load . . . . . . . . ...

45 to 55 kg

Synchromesh assemblies push through load . . . . . ..

8,2 to 10 kgf

Clearance between baulk rings and gears . . . . . . ...

0,38 mm

Fifth gear end float . . . . . . . . . . . . . . . ...

0,020 mm

Third gear end float . . . . . . . . . . . . . . . ..

0,020 mm

Second gear end float . . . . . . . . . . . . . . ..

0,020 mm

First gear bush end float . . . . . . . . . . . . . ..

0,075 mm

First gear end float . . . . . . . . . . . . . . . ...

0,20 mm

Fifth gear synchromesh end float . . . . . . . . . . .

0,005 to 0,055 mm

TORQUE

VALUES

NOTE:

Torque wrenches should

be

regularly

checked for accuracy to ensure that

all

fixings

are tightened to the correct torque.

Nm

7 - 10
7 - 10
7 - 10

7 - 10
7 - 10

22 - 28
22 - 28
22 - 28
22 - 28
22 - 28

22 - 28
22 - 28
22 - 28

7 - 10

40 - 47

2 2 - 28

65 - 80
22 - 28
47 - 54
65 - 80

25 - 35

204 - 231

Oil pump to extension case
Clip clutch release lever
Spool retainer to gearcase
Spool guide

to

remote housing

Extension case to gearcase
Pivot plate, clutch release
Remote housing to gearcase

Gear lever housing to remote housing
Guide, clutch release sleeve
Slave cylinder to bell housing
Front cover to gearcase
Fifth gear support bracket bolts
Plunger housing to remote housing

Gear lever retainer
Lower gear lever

to

extension nut

Reverse lever pivot

post

nut

Clutch housing

to

gearbox bolts

Plug, detent spring and ball

Oil

filter plug

Oil filler

-

level plug

Fifth gear layshaft stake nut

Oil drain plug

Breather

14

-

16

7 - 10

Bottom

cover

to

clutch housing

-

REISSUED:

FEB

1993

41

LT77S MANUAL

GEARBOX

SERVICE TOOLS

NOTE:

Where the use

of

special tools is

specified, only these tools should

be

used to

avoid the possibility

of

personal injury and

or

damage to components.

18G 1400

Remover synchromesh hub and
gear cluster

1 8 G

7 0 5

Puller, bearing remover

18G 1400-1

Adaptor mainshaft fifth gear

18G

705-1A

Adaptor for mainshaft

oil

seal

track and layshaft fifth gear

MS 47

Hand press

18G 705-7

Adaptor for layshaft bearings

18G 47BA

Adaptor input shaft bearing

42

REISSUED: FEB

1993

18G 47BAX

Conversion kit

18G 284

Impulse extractor

18G 284AAH

Adaptor for input shaft pilot
bearing track

18G 1422

Mainshaft rear oil seal replacer

LT77S MANUAL GEARBOX

18G 1431

Mainshaft rear oil seal replacer

18G 1205

Flange holder

REISSUED:

FEB

1993

43

LT77S

MANUAL GEARBOX

LOCALLY MANUFACTURED TOOLS

Tool 'C'. Mild steel dummy centre bearing for the

In addition to the special service tools, the following

tools can be locally made to assist the dismantling
and assembly of the gearbox. The overhaul
procedure is based upon the assumption that these
tools are available.

Tool 'A'. Dual purpose tool. Reverse shaft retainer to
prevent the shaft falling out when the gearbox in
inverted. Also, a layshaft fifth gear retainer to hold
the fifth gear whilst releasing stake nut. Use 5mm
mild steel to manufacture the tool. When using the

tool for the layshaft nut, a suitable spacer is required
20mm diameter 23mm long, with an 8mm diameter
clearance hole.

selection of first gear bush.

Tool ‘D’. Layshaft support plate is fitted with two 8 x
25mm bolts and washers to the front of the gearbox
case. It also supports the input shaft bearing outer
track.

Tool 'B'. Four pilot studs with an 8mm thread for
locating in the four counter sunk blind holes

in

the

workstand.

44

REISSUED: FEB

1993