Content .. 70 71 72 73 ..

Defender 90 / 110 / 130. Manual - part 72

LT77

FIVE SPEED GEARBOX

The latest model gearbox employs a spring-loaded

biased gear change lever assembly and the following

instructions

(212 to 236) include the fitting and

adjustment of this arrangement.

Gear selector housing

212. Refit the gear selector rollers, pin and new circlip

ensuring circlip is not expanded beyond minimum
necessary to obtain entry.

213. Lubricate t h e gear selector housing shaft with

light

oil and fit a new

ring.

214. Insert shaft through the large blanking plug

orifice, ensuring the shaft indent is uppermost.

215. Place the gear selector housing into protected vice

jaws and fit the selector yoke to the shaft, using a
suitable pin punch and new

roll pin. Remove the

housing assembly from the vice on completion.

216. Fit the reverse switch and large blanking plugs.

Coal plug threads with Loctitc 290 and tighten to

217. Refit the fifth gear

spool retainer and tighten the

bolts and washer 7

(5 Ibf

and

fit

a new

nylon insert into t h e trunnion housing and secure

with a n e w circlip.

218. Invert the gear selector housing and fit the

trunnion housing to the sclector

ensuring

the locating bolt aligns with the shaft indent. Coat
the bolt threads with Loctite

Tighten bolt to

the specified torque.

219. Fit a new gear lever gasket and locate the gear

lever

housing, spring washers and bolts. Tighten

bolts

to the specified torque.

220. Fit the two bias spring adjustment screws and lock

nuts.

221. Place the bias spring in position with the spring

legs either side of the gear lever housing and
retain with a roll-pin.

222. Coat the upper and lower spheres of the gear

lever shaft with

Q.5848

or Shell

R I and locate the lever

in t h e gearbox

and retain with the bolt and special lock washer.

223. Using a screw driver lift the bias spring legs over

the gear lever crosspins.

not overstress the

spring legs.

the main gear lever with the

gaiter. Align the marks made when dismantling.

the

‘Nyloc’ n u t .

224. Select first

or second gear. It may bc necessary to

rotate  the  mainshaft  whilst  manipulating the  gear
lever.
Locate  the  reverse  gear plunger  assembly  on  the
right  hand  side viewed  from  rear, giving sufficient
load

on the trunnion to eliminate side play. Whilst

maintaining a light

pressure, measure the

and gear selector casting. Add 0,6

the

measured figure and select suitable thickness
shims to equal the total.

226. Remove the reverse plunger assembly, fit the

required thickness

and refit the plunger

assembly, spring washers and bolts. Tighten to the
specified torque.

the specified torque.

between

casting

227. Fit the fifth gear stop o n

the left hand side viewed

from the rear, giving sufficient load

on the

trunnion

eliminate

side

play.

Whilst

maintaining a light finger pressure, measure the

clearance between t h e plunger assembly casting
and gear selector casting. Add

to the

measured

and select suitable thickness

shims to equal

the total.

228. Remove the fifth gear stop,

fit

the required

thickness

Refit the gear stop assembly,

spring washers and bolts. Tighten bolts to the
specified torque.

229.

To adjust the bias springs with the unit completely
assembled, engage either third or fourth gear.

230. Adjust the two adjusting screws until both legs

the spring are approximately

0,5

clear of the

cross-pin in the gear lever. This should allow a
certain amount

of radial

of the gear

lever without the cross-pin contacting either of

spring legs.

231. Apply a slight load to

t h e

gear lever knob

a left

hand

position the gear lever at one

extreme of the radial play. Adjust the right hand
adjusting screw downwards until the right hand
spring

just makes contact with the cross-pin

o n

the right hand side.

232. Repeat instruction 229

in the opposite direction.

233. At this stage, radial play will still be present, but

at the other extreme the cross-pin should just
make contact with the spring leg on the other side.

the radial play is just eliminated. Tighten
lockn ts.

235. Return gear lever to neutral position and rock

across the gate several times. The gear lever
should return

to the third and fourth gate. If not,

repeat the

procedure.

236. Fit the rubber gaiter and secure with a strap.

TRANSFER

GEARBOX

230 R TRANSFER BOX

The following operations can be carried out with the
gearbox

in the vehicle. For ease of working, the vehicle

should be raised on

a ramp or placed over a pit. Also,

the battery should be disconnected

for safety.

RENEW SPEEDOMETER DRIVE PINION

1. Raise the vehicle on a ramp.

2. Remove the speedomcter drive clamp and nut and

3. Prise out t h e drive pinion assembly.
4. Push in a new assembly and fit the speedometer

withdraw the cable.

cable and secure with the clamp and nut.

RENEW REAR OUTPUT SHAFT OIL SEAL

Special tool:

Disconnect the battery for safety.

2. Disconnect the rear propshaft from the output

Remove

brake drum retaining screws and

4. Remove the two back plate bolts that also retain

flange.

withdraw the drum.

oil catcher and remove the catcher.

NOTE: An hexagonal type socket should be used for
these bolts.

5 .

Remove the output shaft nut and washer and

6. Using

slot provided, lever off the dust cover.

7. Prise out the output shaft oil
8. Using special tool

fit

the doublc-lipped oil

seal, open side inwards, with the seal in contact
with the bearing circlip, taking care not to touch
the seal lips.

withdraw the flange.

NOTE: The double-lipped oil seal supersedes the
two oil seals used on early production.

9. Fit the dust cover.

10. Lubricate the surface of the flange which runs in

the seal and carefully fit the flange.

NOTE: To renew the flange bolts first remove the
circlip before fitting the flange.

11. Secure the flange with the nut and washer and

tighten to 146 to

179

(108 to 132

ft).

rubber sealant and secure with the two back plate
bolts (with plain washers).

13.

Fit

the brake drum and retain with the two screws.

14.

Reconnect

t h e

propeller shaft.

RENEW FRONT OUTPUT SHAFT OIL SEAL

Special tool:

1. Disconnect the front propeller shaft from the

flange and move to one side.

2. Remove the output shaft nut and washer and

withdraw the flange.

3. Remove the oil seal shield.

4. Prise out the

oil

NOTE: The double-lipped

oil

seal supersedes the

two

oil seals used on early production.

5. Using special oil seal replacer tool

fit

the

double-lipped

oil seal, open side inwards, with the

seal in contact with

t h e

bearing circlip, taking care

not to touch the scal lip.

6. Lubricate the running surface of t h e flange and fit

together with the oil seal shield.

7. Secure the flange with t h e nut and washer and

tighten to 146 to 179

to 132

ft).

Refit

the

propeller shaft.

REMOVE INTERMEDIATE SHAFT AND GEARS

Service tool:

Drain the transfer gearbox

oil.

2. Disconnect t h e rear propshaft from the output

flange.

3. Remove the two screws and withdraw

t h e

brake

drum.

4. Remove the four bolts securing the brake back

plate and withdraw the back plate and oil catcher.

NOTE: An hexagonal type socket should be used for
these bolts.

5 .

Remove the

shaft keeper plate,

-.-

retained by a single bolt.

6. Remove the ten bolts and remove the bottom cover

plate.

Using service tool

withdraw

the

intermediate shaft whilst holding the gear cluster.
Collect the bearings and thrust washers from both
ends of the cluster.

Remove the two

rings, one from

shaft, the

other from the casing.

Fit intermediate shaft gears

Fit

t h e

ring into the front

the transfer case.

11. Lubricate thrust washers, bearings, shaft and

12. Fit needle bearings with spacer interposed.
13. Fit front thrust washer to slot

transfer case (plain

14.

Locate gear assembly partially into the transfer

Fit the

ring to

intermediate shaft.

spacer.

side to case).

case

so that

i t

rests o n the front thrust washer.

TRANSFER GEARBOX

15. Locate rear thrust washer (plain side uppermost)

16. Gently push gear assembly

into mesh.

17. Using a screwdriver through the intermediate shaft

hole guide

locating tab

on the rear thrust

washer into the slot provided

in the transfer case.

18. Align gear and thrust assembly and slide the

intermediate shaft into the transfer box from

the

rear.

19. Align the shaft

so that the lock plate in

the

end

on top.

20. Apply Loctite

290 to the lock plate bolt threads.

Locate lock plate into position and fit securing bolt
(with spring washer).

21. Lever the

to one side and measure

the end-float with feeler gauges. This should be
between

and

(0.003 and 0.014 in).

22. Grease and

fit

the bottom cover joint washer.

23. Apply Loctite 290 to the ten bolts and evenly

tighten

(16 to

21 Ibf ft).

24, Fit the oil catcher to the brake plate, using silicone

rubber sealant and secure the backplate with the
four bolts. The t w o bolts securing the oil catcher

are fitted with plain washers.

25.  Fit the brake drum and retain with the two screws.
26.  Connect the rear prop shaft.
27.  Refill

t h e

transfer box with the correct oil.

into

slot in transfer case.

...

....

...

TRANSFER GEARBOX

OVERHAUL

TRANSFER GEARBOX

Service tools:
RO 605862

Intermediate shaft removal

remover

arm.

Flange wrench

pliers

linkage.

Oil seal replacer

- Stake nut remover

MS47

Hand press

Collars

- Button

Collars

1801424

Differential centre bearing drift

Collars and buttons

LST 47-1

Collars

REMOVE

ASSEMBLIES FOR OVERHAUL

(Instructions 1 to 33)

6 .

Disconnect the bottom

of the

connecting

rod from the

operating arm by removing

the split pin and clevis pin.

7. Remove the plastic bushes from the operating

Remove the gearchange housing complete

with

Having removed the complete gearbox and

transfer box assembly. The transfer box is
separated from the gearbox on the work bench.

NOTE: To facilitate removal of various items on

the work bench, obtain suitable wooden blocks to
enable the transfer box to be turned and propped
up

required.

Hand brake linkage removal

2. Remove the split pin and clevis pin

release the

handbrake linkage from the brake operating
lever.

3 . Remove the two bolts (with spring washers)

securing

t h e

rear end of the handbrake mounting

bracket

the casing, the lower bolt is shorter.

Remove the two bolts (with spring washers and

distance pieces) securing the front sidc

of the

handbrake mounting bracket and remove from
the transfer box.

Transfer

box

mounting removal

5 .

Remove the bolts retaining the right hand rubber

mounting plate.

Content .. 70 71 72 73 ..