Land Rover Defender 90 - 110 - 130 Workshop Manual
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425DDEFENDER
90.110 130
DEFENDER
LT77S GEARBOX
WORKSHOP MANUAL SUPPLEMENT
Publication Number SLR 621 EN WS 2
1 ,
Published by the
Technical Publications Department of
Land Rover
Lode Lane
Solihull
West Midlands, 892 8NW
England
@ Copyright Land Rover 1991
37 . MANUAL GEARBOX
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CONTENTS
Page
OVERHAUL
DISMANTLE ..................................................................................................... 1
GEAR SELECTOR HOUSING .......................................................................... 1
EXTENSION HOUSING .................................................................................... 2
MAINSHAFT AND LAYSHAFT FIFTH GEARS .................................................. 3
REVERSE SHAFT, LAYSHAFT AND MAINSHAFT ........................................... 5
DISMANTLE MAINSHAFT ................................................................................ 7
GEARBOX CASINGS AND OIL PUMP ............................................................. 8
GEAR CHANGE HOUSING ............................................................................ 10
GEAR SELECTOR HOUSING ........................................................................ 12
SYNCHROMESH ASSEMBLIES .................................................................... 15
CHECKING BAULK RING CLEARANCES ...................................................... 17
INPUT SHAFT ................................................................................................ 18
MAINSHAFT ................................................................................................... 18
MAINSHAFT GEAR END FLOAT CHECKS .................................................... 19
ASSEMBLING MAINSHAFT ........................................................................... 21
LAYSHAFT ..................................................................................................... 23
REVERSE GEAR AND SHAFT ...................................................................... 23
SELECTORS .................................................................................................. 24
ASSEMBLING GEARBOX SHAFTS TO CENTRE PLATE .............................. 25
FITTING GEARBOX CASING ......................................................................... 27
FITTING FIFTH GEAR .................................................................................... 28
FIFTH GEAR SELECTOR FORK ASSEMBLY ................................................ 30
EXTENSION CASE ........................................................................................ 31
INPUT-MAINSHAFT BEARING ADJUSTMENT .............................................. 32
LAYSHAFT BEARING ADJUSTMENT ............................................................ 32
GEAR LEVER AND REMOTE HOUSING ASSEMBLY ................................... 33
BELL HOUSING - FOUR CYLINDER ENGINE ............................................... 35
BELL HOUSING - V8 ENGINE ....................................................................... 35
SPECIFICATIONS. TORQUE
DATA ............................................................................................................... 1
TORQUE VALUES ........................................................................................... 1
SERVICE TOOLS
SERVICE TOOLS ............................................................................................. 1
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37 - MANUAL GEARBOX
CONTENTS
Page
LOCALLY MANUFACTURED TOOLS .............................................................. 3
GEARS AND SHAFTS ..................................................................................... 5
GEARBOX CASING ......................................................................................... 7
LT77S MANUAL GEARBOX
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DISMANTLE
Bell housing - four cylinder engine
1. Remove transfer box, drain oil and clean
exterior.
2. If fitted, clutch release bearing clip.
3. Remove clutch release assembly.
4. Remove one pivot post bolt, slacken the other
and move post aside.
5. Remove six bolts and withdraw bell housing.
GEAR SELECTOR HOUSING
1. Remove four bolts and remove main gearbox
selector housing.
2. Remove transfer box housing.
3. Remove remaining bolts and remove remote
housing.
Bell housing - V8 engine
1. Remove clutch release bearing.
2. Remove screw and spring clip and remove
release lever.
3. Remove " C" clip from pivot post.
4. Remove six bolts and bell housing.
I 37 MANUALGEARBOX DEFENDER
4. Drive out quadrant roll pin.
5. Move selector shaft forward to remove
quadrant.
n
5
ST2180M
2. Using service tool 18G 705 and 18G 705-1A
withdraw the oil seal collar.
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18G 705
3. Remove the fifth gear extension housing.
4. Secure the centre plate to the gearcase with
EXTENSION HOUSING . two 8 x 35" bolts.
1. Remove snap ring retaining oil seal collar.
ST2316M
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LT77S MANUAL GEARBOX
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MAINSHAFT AND LAYSHAFT FIFTH GEARS
1. Remove mainshaft "0" ring.
2. Remove oil pump drive shaft.
3. Remove " E" clips from selector fork.
4. Remove fifth gear selector Spool.
5. Remove selector fork bracket.
9. Remove circlip retaining mainshaft fifth gear
synchromesh.
10. Fit special tool 18G 1400-1 and 18G 1400 as
illustrated.
137 MANUALGEARBOX DEFENDER
11. Remove fifth gear synchromesh.
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ST2296M 3. Invert gear case and locate studs in workstand -
holes.
12. Remove layshaft fifth gear using special tools 4. Remove selector shaft spool retainer.
18G 705 and 18G 705-1A.
18G705-1A
Main gear case.
1. Secure reverse shaft retainer, manufactured
tool "A"; to centre plate.
2. Fit studs, manufactured tool"B" to gear case.
4 1 OVERHAUL
LT77S MANUAL GEARBOX
5. Remove front cover and gasket.
6. Retrieve selective washers.
REVERSE SHAFT, LAYSHAFT AND MAINSHAFT
1. Remove retainer (tool " A" ) and reverse shaft.
2. Remove thrust washer, reverse gear and
spacer.
3. Remove reverse lever pin with " E" clip
attached.
4. Remove lever and slipper pad.
7. Remove bolts and lift-off gear case.
8. Secure centre plate with nut and bolt.
ST23OlM Yt II I
I 37 MANUALGEARBOX DEFENDER
5. Remove input shaft and fourth gear baulk ring.
6. Remove layshaft by tilting, as illustrated and
lifting mainshaft.
5
ST
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ST3245 M
U
7. Unscrew plug and remove spring and outboard
detent ball.
8. Align fifth gear selector pin with centre plate
slot.
9. Remove mainshaft, gears, selectors and forks.
10. Remove selector fork assembly from gears.
11. Collect inboard detent ball and spring from
centre plate.
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$31.99
Get your hands on the Land Rover Defender 90 - 110 - 130 Workshop Manual, a comprehensive resource for maintaining, servicing, diagnosing, and repairing your vehicle. This complete FSM covers the years 1984 - 1990 and is suitable for other years of manufacture as vehicles are made in generations. Whether you're a professional mechanic or a DIY enthusiast, this manual is packed with valuable information and diagrams for all service and repair procedures.
The manual includes general specification data, engine tuning data, torque wrench settings, general fitting instructions, lubricants, fluids and capacities, maintenance, and detailed sections on the engine, fuel systems, cooling systems, gearboxes, transfer gearboxes, propeller shafts, differentials, steering, suspension, braking system, chassis, body, heater, air conditioning, and electrical systems for both 90 and 110 models.
Additionally, the 90/110/130 Supplement provides further insights into engine 200Tdi, fuel systems, cooling systems, manifolds, exhaust, steering, and electrical components. The manual is in English and is available in a .RAR file format, which requires appropriate software for extraction. If you encounter issues with downloading, consider using a download manager to avoid timeouts. For any further assistance, feel free to reach out to us.
With this manual at your disposal, you can access a wealth of information covering various aspects such as engine mechanical, lubrication and cooling systems, fuel and emission control systems, transmission, suspension, brake system, steering, electrical system, and more. This resource is a must-have for anyone looking to effectively maintain and repair their Land Rover Defender 90 - 110 - 130.
