Defender (1993+). Manual — part 51

LT77S MANUAL GEARBOX

Tool 'E'. Workstand for securely locating the gearbox
during overhaul. Manufacture from 30mm x 30mm
angle iron. The single hole marked 'A' should be
drilled through the material with a 10mm drill.

The four counter sunk blind holes marked 'B' should
also be made with a 10mm drill, but must not be
drilled through the material.

REISSUED: FEB

1993

4 5

LT230T TRANSFER GEARBOX

REMOVE LT230T TRANSFER GEARBOX FROM

THE LT77S

GEARBOX

Special Tool: 18G 1425-LRT-41-009

-

Guide studs

(3) also locally manufactured adaptor plate, see
below

Adaptor plate for removing transfer gearbox

The transfer gearbox should b e 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

LT230R transfer gearbox,

it

can be modified to suit

both the LT230R and LT230T gearboxes

by

making

the modifications shown by the large arrows.

WARNING: Where the use

of a transmission

hoist is necessary,

it

is absolutely essential to

follow the manufacturers' instructions to ensure

safe and effective use of the equipment.

Material. Steel plate BS 1449 Grade 4 or 14
Holes marked thus * to be drilled to fit hoist being

used.

REISSUED: FEB 1993

1

LT230T TRANSFER GEARBOX

22. Lower the hoist and withdraw the transfer

box

Removing

from the vehicle,

1.

Install the vehicle on a ramp.

2.

Disconnect the battery.

3. Remove the' cover panel from the right-hand

seat base.

4.

Remove the breather pipe union from the

transfer gearbox high/low cross-shaft housing.

5.

Disconnect the high/low lever.

6.

Disconnect the transmission brake cable at

the clevis joint.

7. Raise the vehicle on the ramp and drain the

oil from the transfer box.

8.

Remove the centre section of the exhaust

system.

9.

Disconnect the front and rear propeller shafts

from the gearbox and move them aside.

10. Disconnect the speedometer cable from the

transfer gearbox.

11.

Remove the split pin at the lower end of the
pivot arm for the differential lock control.

Then, remove the two bolts securing the pivot
arm to allow the link

to be

disconnected. Later

models disconnect the connecting link from

the differential lock lever.

12. Manufacture an adaptor plate

in accordance

with the drawing, to attach to the gearbox
hoist and transfer box to facilitate removal
(RR244M).

13.

Place

four, 30 mm (1.250 in) long spacers

between the top of the hoist and the adaptor
plate at the securing points and secure the

23.

Make sure that the joint faces of the transfer

adaptor plate

to

the hoist.

14.

Remove the four central bolts

from the

box and main gearbox extension case are

transfer box bottom cover, move the hoist into

clean and that the three guide studs, 18G

position and secure the adaptor plate

to the

1425, are fitted

to the extension case.

transfer box.

24. Lubricate the oil seal

in the joint face of

15. Adjust the hoist to take the weight of the

transfer box, secure the transfer box

to

the

transfer box.

adaptor plate on the lifting hoist and raise the

16.

Remove three nuts and bolts securing the

hoist until the transfer box can be located over

right- hand gearbox mounting bracket

to the

the guide studs.

chassis, then remove the nut from the rubber

25. Remove the guide

studs and secure the

mounting and withdraw the bracket.

transfer box

to me main gearbox extension

17. Place a suitable wooden block between the

case. Tighten the nuts and

bolts

to the correct

main gearbox and chassis cross-member,

torque.

the wooden block.

the removal sequence, noting the following

18. Disconnect .the electrical lead from the

important points.

differential lock switch.

27. After removing the lifting hoist and adaptor

19.

Move the small crank lever, for the high/low

plate

from

the transfer box, clean the threads

selector, upward

to

allow access

to

the

of the four bolts for the transfer box bottom

adjacent nut securing the transfer box to the

cover, coat them with Loctite

290,

and

fit

them

main gearbox extension case. Later models

together with spring washers. Tighten

to

the

remove the lower lock nut from the high-low

correct torque.

operating rod.

28. Refill the transfer box

with

the correct grade

20.

Remove the two nuts and four bolts securing

oil

to

the oil level plug hole.

the transfer box

to the main gearbox

29. Check, and

if

necessary top up, the oil level in

extension case.

the main gearbox. Use the correct grade oil.

21. Fit three guide studs, 18G 1425, through the

30. Check the operation of the handbrake and

transfer box bolt holes

to

support

it

during

adjust as necessary.

removal.

Refitting

then lower the hoist until the gearbox contacts

26. Complete the refitting procedure b

y

reversing

2

REISSUED:

FEB

1993

LT230T TRANSFER GEARBOX

OVERHAUL

Service

Tools:

18G47 - 7

Input gear cluster bearing cones
remover/replacer

18G47BB -1

Adaptor

centre

differential

bearing

remover

18G47BB - 3 Adaptor

centre

differential

bearing

remover button

18G1205

Drive flange wrench

18G1271

Oil seal remover (optional)

18G1422

Mainshaft rear oil seal replacer

18G1423

Adaptor/socket

centre

differential

Locknut remover/replacer

18G1424

Centre differential bearing replacer

MS47

Hand press

MS550
LST47 - 1

Adaptor

centre differential bearing

LST104

Intermediate gear dummy shaft

LST105

Input gear mandrel

LST550 - 4 Intermediate gear bearing replacer

NOTE: Where the use of special service tools is
specified, only these tools should be used to
avoid the possibility of personal injury and or
damage to components.

Bearing and oil seal replacer handle

remover