Defender (1993+). Manual — part 42

LT77S MANUAL GEARBOX

12. Using extractor tool 18G 705 and collets 18G

705-7, withdraw layshaft bearings.

DISMANTLE MAINSHAFT

1. Remove circlip retaining first gear assembly.

11. Collect inboard detent ball and spring from

centre plate.

2. Remove taper bearing, bush, needle bearing,

first gear spacer, cone, inner and outer baulk
rings.

3.

Remove circlip to release first and second

gear synchromesh assembly.

LT77S

MANUAL GEARBOX

5.

Remove first and second synchromesh baulk

rings.

6.

Using

MS

47

and support bars under second

gear, press

off pilot bearing, third, fourth

synchromesh second and third gear assembly.

4.

With

MS

47

press first gear assembly

from

mainshaft.

7.

Remove washer, third, fourth synchromesh,

third gear baulk ring, split needle rollers, bush,
needle bearing and second gear.

8. Remove snap ring, spacer, second gear cone

and circlip.

LT77S

MANUAL

GEARBOX

GEARBOX CASINGS AND OIL PUMP

Degrease and clean all components and discard
gaskets and seals.

Gearbox casing

1.

Remove mainshaft and layshaft bearing

tracks.

2. Remove plastic scoop from inside the casing.

Centre plate

1.

Remove bearing tracks.

2. Inspect for damage and selector rail bore for

wear.

3.

Temporally

fit

reverse shaft gear and lever

and check clearance between slipper and
lever does not exceed

0,20

mm

(0.008

in).

Extension

case

3.

Inspect case for damage, cracks and stripped

threads.

1.

Examine for damage

to

threads and machined

4.

Fit

a new scoop with scoop side towards top

of casing.

2. Remove oil pump cover, inspect gears and

faces.

housing and renew

if

required.

Front

cover

1.

Remove oil seal from cover.

Do not

fit

a new

seal at this stage

LT77S

MANUAL

GEARBOX

3. Check oil pick up pipe for obstruction but do

not remove.

4. Remove drain plug assembly. Clean and

renew filter and washers

if

necessary.

5.

Renew oil seal.

6.

Renew Ferrobestos bush.

WARNING: This bush contains asbestos.

Do

not

attempt to clean it. Poisonous substances.

7.

Fit new bush with drain holes towards bottom

of

casing.

CAUTION:

If

drain holes are not positioned

correctly oil may build up behind

oil seal and

cause a leak.

9. Fit

oil seal

to

housing, lip side leading, using

18G 1422. Apply SAE 40

oil

to

lip.

10.

Assemble gears to oil pump and fit cover.

8.

If extension housing is being renewed transfer

grub screw

to

new housing.

Apply Loctite

to

threads.

GEAR CHANGE HOUSING

1.

With

a length

of tube, release the bias spring

from adjusting screws.

2. Remove bias spring adjusting screws.