Defender (1993+). Manual — part 49

LT77S MANUAL GEARBOX

NOTE: If necessary, final adjustment can

be

Bias spring adjustment

made

in

vehicle. To increase pull-over load turn

screw clockwise

or anti-clockwise to reduce load.

Fifth gear stop screw adjustment.

NOTE: The purpose of this adjustment

is

to

set

both bolts so that the bias spring legs apply

equal pressure on both ends

of the gear lever

cross pin

when third or fourth gear

is engaged.

This will ensure that when the lever i s

in neutral,

distance across corners of locknut.

the gear change mechanism

is

automatically

aligned for third

or fourth gear selection.

1.

Adjust screw to protrude from housing the

NOTE: This is only an approximate setting which
will limit travel of selector yoke

but will allow

fifth gear

to

be selected.

1.

Select fourth gear and

lift

both spring legs

over the cross pins.

2.

Turn adjustment bolts until heads touch spring

legs.

3. Apply light pressure to gear lever

to

the right

and adjust left hand bolt.

NOTE: Clearance between spring leg and bolt
0,05 mm

(0.002

in.) using feeler gauge.

4.

Move lever to left and adjust right hand bolt to

clearance.

5. Tighten locknuts.

2. Select fifth gear. While applying light pressure

to

gear lever towards right,

turn

screw

clockwise until

it

contacts yoke. Turn screw

half a turn anti- clockwise and tighten nut.

REISSUED:

FEB

1993

37

LT77S

MANUAL

GEARBOX

GEARS AND SHAFTS

2.

Interlock spool.

3. First

-

second fork and selector rail assembly.

4. First

-

second synchromesh.

5. First gear synchromesh outer baulk ring.

6.

First gear synchromesh inner baulk ring.

7.

Cone.

9.

First gear.

BELL HOUSING

1.

Third

-

fourth selector fork.

1. Fit bell housing locating on hollow dowels.

NOTE: Fit the 12

x

45mm

bolts through dowels

and

12

x 30mm bolts

in

remaining positions.

2. Apply molybdenum disulphide grease to pivot

8. Thrust washer.

post, release lever, socket and push rod. Not

the bearing guide.

10. Needle roller bearings.

3. Fit

'C'

washer

to pivot post.

11.

First gear selective bush.

4. Fit spring clip to lever and

fit

lever

to pivot

post.

13. Circlip.

12. Centre taper roller bearing.

14. Thrust washer.

NOTE: Position spring clip behind 'C' washer

15. Fifth gear.

and tighten screw.

16. Fifth gear baulk ring.
17. Fifth gear synchromesh.

19. Fifth gear synchromesh selective washer.

20. Circlip.
21. “O” ring.

22.

Oil seal collar.

23. Snap ring.
24. Fourth gear baulk ring.
25. Pilot taper bearing.
26. Spacer.
27. Third

-

fourth synchromesh.

28. Third gear baulk ring.
29. Third gear.
30. Third gear bush.
31. Second gear.
32. Thrust washer.
33. Cone.
34. Second gear synchromesh inner baulk ring.
35. Second gear synchromesh outer baulk ring.
36. Mainshaft.
37. Input shaft bearing track and selective washer.

38. Input shaft.
39. Input shaft taper bearing.
40. Fourth gear.
41. Selective shim.
42. Taper bearing.
43. Layshaft

fourth

gear.

44.

Layshaft third gear.

45.

Layshaft second gear.

46. Layshaft reverse gear.
47. Layshaft first gear.
48. Taper bearing.

49.

Layshaft fifth gear.

50.

Layshaft fifth gear retaining stake nut.

51. Circlips

-

first

gear

and

first-second

synchromesh.

52. Snap ring

-

second gear cone and spacer.

53. Spacer.

54.

Snap ring.

55. Reverse idler gear.
56. Thrust washer.
57. Snap ring.
58. Fifth gear spool.

5. Fit bearing and retain with plastic staple.

18. Fifth gear synchromesh back plate.

38

REISSUED:

FEB

1993

LT77S MANUAL GEARBOX

REISSUED:

FEB

1993

39

LT77S MANUAL GEARBOX

GEARBOX CASING

14.

Selector plug, detent ball and spring.

15.

Gasket.

1. Front cover.

16. Fifth gear selector bracket.

2.

Front cover oil seal.

17. Fifth gear selector

fork.

3.

Front cover gasket.

18. Reverse gear shaft.

4.

Oil drain plug and washer.

19. Oil pick-up pipe.

5. Oil level plug.

20. Oil pump drive shaft.

6.

Gearbox main casing.

21. Oil pump gears and cover.

7.

Spool retainer.

22. Fifth gear extension housing.

8. Gasket.

23. Fifth gear extension housing drain plug and

9. Inboard detent ball and spring.

filter.

10. Reverse lever and slipper.

24. Ferrobestos bush.

11. Locating dowels

-

centre plate to maincase.

25. Oil seal.

12. Reverse lever pivot post.

13.

Centre plate.

40

REISSUED:

FEB

1993