Defender (1993+). Manual — part 40

LT77S MANUAL

GEARBOX

REMOVE LT77S MANUAL GEARBOX AND

LT230

11.

Release the air filter

hose

at

filter.

TRANSFER BOX

12.

Raise the ramp.

13.

Remove the eight nuts and bolts securing the

WARNING: Where the use

of a transmission

chassis cross member and using a suitable

hoist is necessary,

it

is absolutely essential to

means of spreading the chassis, remove the

follow

the

manufacturers' instructions to ensure

cross member.

safe and effective use of the equipment.

14. Place

a suitable container under the

transmission, remove the three drain plugs,
allow the oil to drain and refit the plugs. Clean
filter on the extension housing plug before
refitting.

15.

Remove the intermediate exhaust pipe and
silencer section as

follows:

(a) Release the connection to the front pipe

at the flange.

(b) Release the connection

to

the rear section

at the flange immediately behind the
silencer.

(c) Remove the

'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 the
rear

of the transfer box.

19.

Disconnect the handbrake inner cable by
removing the split pin and clevis pin.

20. Slacken the retaining nuts and release the

handbrake outer cable from the bracket.

21.

Remove the 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 it

to

a transmission

hoist.

To achieve balance of the transmission

unit when mounted on the transmission hoist,

it

is essential that point A is situated over the

centre

of the lifting hoist ram. Drill fixing holes

1.

Install the vehicle on a ramp.

B

to suit hoist table. Secure the transmission

2. Disconnect the battery.

unit to the lifting bracket at point

C,

by means

3. Remove the gear lever knob.

of the lower bolts retaining the transfer

4.

Remove the transfer and differential lock

gearbox rear cover.

knob.

23.

Remove the bottom

two

bolts

from the transfer

5. Remove the gear lever cover.

box rear cover and use them

to

attach the

6. Remove the

10

mm Nyloc nut and plain

rear end of the cradle to the transfer box.

washer. Mark the gear lever spline setting and

Ensure that the tube in the centre

of the

detach the gear lever and gaiter from the

cradle locates over the extension housing

splined lower gear lever.

drain plug.

7.

Select high range to prevent the transfer

24. Raise the hoist just enough to take the weight

gearbox selector lever fouling the tunnel when

of the transmission.

removing the gearbox.

25. Remove the three nuts and bolts securing the

8.

Remove the bonnet.

transfer box LH and

R H mounting brackets

9.

Remove the nuts and bolts retaining the fan

to

the chassis.

Cowl to the engine and move the cowling

26.

Remove the nuts retaining the brackets to

the

forward, clear of the engine.

speedometer cable, and starter motor harness
from clips at rear of the engine.

mounting rubbers and remove the brackets.

10. Release the transmission breather pipes,

27.

Lower the hoist sufficiently to allow the

transfer lever to clear the transmission tunnel
aperture.

28. Disconnect the four-wheel drive indicator

electrical lead (bullet connection).

LT77S MANUAL

GEARBOX

MATERIAL AND WELDING SPECIFICATION

Steel Plate

Tube

BS

4848 (Part 2)

BS 1449 (Grade 4 or

14)

Arc Welding

BS 5135

operating rod.

29. Remove the cleat retaining the reverse light

40.

Remove the breather pipes.

switch wires from the

RH

side of the

gearbox.

30. Disconnect the wire from the reverse light

switch situated at the top rear

of

the selector

housing and move the harness away from the

transmission.

31. Support the engine under the sump with a

jack, placing timber between

the

jack pad and

sump.

32. Remove the eleven bell housing nuts.
33. Withdraw the transmission whilst ensuring all

connections to the engine and chassis are

released.

Separating the transfer

box

from gearbox

34.

Remove the transmission assembly from the
hoist and cradle and install it safely on a
bench.

35.

Remove the four bolts securing the transfer
gear change housing to the remote gear
change housing.

36.

Remove the

two

bolts retaining the cross shaft

lever pivot bracket to the extension housing.

37.

Release the connecting link from the

differential

lock

lever.

38.

Disconnect the pivot arm from the high/low

shaft.

39

Remove the lower lockout from the high/low

LT77S MANUAL GEARBOX

41. Hoist the transfer box into position ensuring

that the loose upper dowel is fitted, Assemble

to

the

main gearbox extension housing and

secure with the four bolts and

two

nuts.

42. Reverse instructions

37 to 40.

59.

Check that the three drain plugs are tight and
remove the main gearbox and transfer box
filler level plugs. Fill the main gearbox with a
recommended

oil until

it

begins to run out of

the filler level hole. Fit and tighten the filler
plug. Similarly remove the transfer filler level

plug and inject a recommended oil until it runs

out of the filler hole. Apply Hylosil to the

43. Fit the cradle

to

the transmission hoist and the

threads and fit the plug and wipe away any

transmission

to the cradle as described in

surplus oil.

instruction 23. Smear Hylomar on bell housing

60. Line up the marks and

fit

the front and rear

face mating with engine.

propeller shafts to the transfer box.

44. Locate the gear lever temporarily and select

61. Fit the exhaust system, and evenly tighten the

any gear in the main gearbox

to

facilitate

flange nuts and bolts. Fit the

'U'

bolt and

entry of the primary shaft.

secure

to

the bracket.

45. Position and raise hoist and

fit

the

62. Expand the chassis side members, fit the

transmission

to

the engine whilst keeping

cross member and secure with the eight nuts

wires and pipes clear to prevent trapping.

46. Secure the transmission

to

the engine with the

eleven nuts, noting that the top RH nut holds
a

clip for

the speedometer cable.

47. Position the reverse

light

wires

to

the

RH

side of the main gearbox and secure with a
cleat

to

the breather pipes.

67.

Fit

main

gear lever gaiter and lever,

to

48. Connect the reverse light wire

to

the switch at

previously marked spline setting. Secure with

the top rear of the selector housing.

the

10

mm 'Nyloc' nut (with plain washer)

to

49, Connect the differential lock indicator wires

the correct torque.

(bullet connection).

68.

Fit the cover to both gear levers and the

50.

Raise the transmission

to

line-up with the

knobs.

engine and ensure that the transfer lever
clears the tunnel aperture.

51. Fit the transfer box LH and RH mounting

brackets but only part ially tighten the securing
nuts and bolts.

52.

Loosely

fit the rubber mounting nuts and lower

the transmission

onto

the mountings. Fully

tighten all the securing nuts and bolts.

53.

Remove the supporting jack from under the

engine sump.

54.

Remove the

two

bolts securing the cradle

to

the transfer

box and remove the cradle and

hoist.

55.

Refit the two bolts using Loctite 290 on the

threads and note that the

L H bolt holds a clip

for the speedometer cable.

56. Fit the slave cylinder using Hylosil

on

the

gasket and tighten the two bolts evenly to 22
to 28 Nm.

57. Fit the handbrake cable using a new split pin

to secure the clevis pin. Grease the clevis and
tighten the outer cable lock nuts.

58. Connect the speedometer cable.

Fitting main gearbox and transfer box to engine

64. Clip the breather pipes, speedometer cable

and starter motor harness

to

rear

of

engine.

65. Fit the fan cowl.
66. Fit the bonnet.

and bolts (four each side).

63. Fit the heater pipe clamp.

DISMANTLE

Bell

housing

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.

EXTENSION HOUSING

1.

Remove snap ring retaining oil seal collar.

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.

4.

Drive out quadrant roll pin.

5.

Move selector shaft forward to remove

quadrant.