Defender (1993+). Manual — part 41

2. Using service tool

18G

705

and

18G

705-1A

withdraw the

oil

seal collar.

LT77S MANUAL GEARBOX

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.

3.

Remove

the fifth

gear extension housing.

4.

Secure the centre plate to

the gearcase with

two

8

x

35mm bolts.

6.

Locate flange holder

tool

18G 1205.

7.

Fit manufactured

tool

"A" and spacer to

restrain layshaft fifth gear.

8.

De-stake and remove fifth gear

nut.

LT77S MANUAL GEARBOX

9.

Remove circlip retaining mainshaft fifth gear

synchromesh.

10.

Fit special

tool 18G 1400-1 and 18G 1400 as

illustrated.

CAUTION: ensure the puller feet locate in the two

cut-outs

in

18G 1400-1

and between the pins.

11.

Remove fifth gear synchromesh.

12. Remove layshaft fifth gear using special

tools

18G

705

and 18G 705-1A.

Main gear case.

1.

Secure reverse shaft retainer, manufactured

tool "A, to centre plate

2. Fit studs, manufactured tool "B" to gear case.

LT77S MANUAL GEARBOX

5. Remove front cover and gasket.
6. Retrieve selective washers.

7.

Remove bolts and

lift-off

gear case.

8.

Secure centre plate with nut and bolt.

3.

Invert gear case and locate studs in

workstand holes.

4.

Remove selector shaft

spool

retainer.

LT77S

MANUAL GEARBOX

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.

5.

Remove input shaft and fourth gear baulk ring.

6.

Remove layshaft by tilting, as illustrated and
lifting mainshaft.

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.