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LT77 FIVE SPEED GEARBOX REMOVE LT77 FIVE SPEED GEARBOX AND 230R TRANSFER BOX - FOUR CYLINDER MODELS 1. Install the vehicle on a ramp. 2. Disconnect the battery. 4. Remove the transfer and differential lock knob. 5 . Remove the gear lever cover. 6. Remove t h e 10 Nyloc nut and plain washer. Mark the gear lever spline setting and the gear lever and gaiter from the splined lower gear 7. Select high range to prevent the transfer gearbox selector lever fouling t h e tunnel when removing the 8. Remove the bonnet. 9. Remove the nuts and bolts retaining the fan cowl to the engine and move the cowling forward, clear of 10. Release the transmission breather pipes, speedometer cable, and starter motor harness from 11. Release clamp holding heater pipes on top of engine to prevent heater inlet pipe fouling the engine. 12. Raise the ramp. chassis cross member and using a suitable means of 14. Place a suitable container under the transmission, remove the three drain plugs, allow the oil to drain and refit plugs. Clean filter on extension housing plug before refitting. 15. Remove t h e intermediate exhaust pipe and silencer section as follows: (a) (b) (c) Release the connection to the front pipe at Release t h e connection to the rear section at 'U' bolt retaining the pipe to the bracket attached to the transfer box. 16. Mark the flanges for reassembly and disconnect the front propeller shaft from the transfer box. 17. Similarly, disconnect the rear propeller shaft. 18. Disconnect the speedometer cable from rear of the transfer box. 20. Slacken t h e retaining nuts and release the handbrake outer cable from t h e bracket. 21. Remove t h e two bolts and withdraw the clutch slave cylinder from the bell housing. 22. Manufacture a cradle to the dimensions given in the drawing and attach i t to a transmission hoist. To achieve balance of the transmission unit when mounted on the transmission hoist, it is essential A is situated the centre of the lifting hoist ram. Drill fixing holes B to suit hoist table. Secure the transmission unit to lifting bracket at point C, by means of the lower bolts retaining 23. Remove the bottom two bolts from the transfer box rear cover and use them to attach rear end of t h e cradle to the transfer box. Ensure that the tube in the centre of the cradle locates over the extension housing drain plug. 24. Raise the hoist just enough to take the weight of the transmission. \ U \ 0 5.0 6.0 A N C 0 5.0 6.0 222.0 ( P a r t 5135 1 |