Defender 90 / 110 / 130. Instruction - page 78

LT 95 FOUR

SPEED GEARBOX

REMOVE

AND

OVERHAUL

MAINSHAFT

TRANSFER GEAR

Special tool:

-

mainshaft output gear puller

Remove

mainshaft rear bearing housing.

2. Lift out the roller bearing.
3. Remove the snap-ring.
4. Withdraw the shim washer.

5 .

transfer gcar is retained on the splines with

Loctite 275. Use

a puller 1861388 to withdraw it.

NOTE: The roller bearing outer race is located by a

roll

pin which

be punched-out before the race can be

removed.

Assembling

Fit the transfer gear to the mainshaft.
Fit the shim washer and snap-ring.
Check the end-float between

the

washer and

snap-ring. End-float to be

0,050

(0.002 in)

maximum. Shim washer range

to

(0.071 to

0.079 in) in

(0.002 in) stages.

Fit

the roller bearing and rear bearing housing.

REMOVE

AND

OVERHAUL

INTERMEDIATE

GEARS ASSEMBLY

Special tool:

-

slave intermediate shaft

Remove t h e speedometer drive housing.

2. Remove the gearbox bottom cover.
3. Screw a suitable extractor into the 8

hole provided

in the intermediate gear shaft.

4.

Hold the intermediate gear cluster

in

position and

withdraw the shaft.

5.

the slave shaft

to

retain together the

gears assembly.

6. Withdraw the intermediate gears assembly.
7. Slide the thrust washers, bearings and gears from

8. The input gear and outer member is a riveted

the slave shaft.

assembly and no dismantling is permitted.

9. Remove the

ring seal from the intermediate

gear shaft.

Wash and degreasc all parts and

for wear

and renew

if necessary. When new, the thrust

bearing washers have a

coating, i f this only

has worn away there is no need

to renew them.

Assemble intermediate gears

11.

Place the slave shaft on t h e bench, extractor thread
end uppermost.

12.

Fit a pear-shaped thrust washer, inner ring and a

thrust bearing washer to the shaft (ring grooved
face downwards).

13.

Fit a needle-roller bearing and the ‘high’ gear
(plain face first) to t h e shaft.

41

LT 95 FOUR SPEED GEARBOX

ST12

1 OM

14.

Position a thrust bearing washer on the ‘high’ gear.

15. Fit a spacer,

bearing and

a further

spacer to the input gear inner

16. Position

assembled input gear on the shaft and

engage the lower spacer

in the previously

positioned thrust bearing

17. Locatc a thrust bearing washer over

upper

spacer.

18. Fit a needle roller bearing and the ‘low’ gear (plain

side last)

to

the shaft.

19.

Fit the remaining thrust needle bearing, inner ring

and thrust washer (ring grooved face upwards).

42

20. When the foregoing bearing clearance check has

been completcd.

the

and slave

shaft

assembly into

transfer gearbox and

selector forks.

21.

Withdraw the slave shaft and lubricate the bearings

through the shaft aperture.

22.

Fit the intermediate shaft and

ring

with

the

flat on the shaft toward

t h e

differential u n i t .

Measure the clearance between the rear thrust

washer and the gear casing. This must be

to

(0.006 to

0.009 in).

24. Adjustment is carried out by substituting one or

both of

thrust washcrs. The washers are

available

in

(0.139 in),

(0.143 in) and

(0.147 in) thicknesses.

Refit the gearbox bottom cover.

26. Refit the speedometer drive

housing.

.

,

..

...

..:

LT

95 FOUR SPEED GEARBOX

REMOVE AND OVERHAUL DIFFERENTIAL UNIT

Special tool:

- bearing extractor

Select the differential lock.

2. Rcmove

differential lock actuator assembly

3. Remove the front output shaft and housing.
4. Remove the speedometer drive housing.

Remove the intermediate cluster assembly.

6.

Remove the differential assembly.

NOTE: During dismantling it is essential that

all

components are marked in their original position and
relative to other components,

so that if original

components are refitted, their initial setting

is

maintained.

7.

Press off the roller bearings using tool

8. Withdraw the high-speed gear, which is secured by

Loct i tc.

I

I

9. Remove the fixings, low-speed gear to casing.

10.

Withdraw the gear.

11. Remove the casing securing bolts.
12. Lift off

t h e

rear

case assembly (and oil retaining

ring

-

later gearboxes).

13. Withdraw the side gear (and thrust washer

-

later

boxes).

14. Slidc

out the cross-shafts and

the bevel

pinions and thrust washers from the front case
assembly.

15. Withdraw the side gear (and thrust washer

-

boxes)

to

the front case assembly.

NOTE: From gearbox numbers 1300

and 1700

the following modifications have been made to

the differential.
A. Introduction of side gear bushes.

Improved thrust washers.

C. Addition of thrust washer on side gears.

Modified cross pins.

E. Addition of oil retaining ring.

The new differential part number FRC 7740

is

only

interchangeable with superceded unit part number
340.

43

LT 95

FOUR SPEED GEARBOX

NOTE: If replacements are required, replace the

following items

16

and 17 as sets.

16. Bevel pinions and side gears (set of six).
17. Cross-shafts (set of
18. Check the gear teeth for damage.
19. Check all parts for satisfactory general condition

including the sidc gear bushcs.

NOTE: The differential case halves are a matched
pair, and halves must not be changed individually.

Assemble differential to gearbox

27. Refit the differential unit.
28. Refit

speedometer drive housing.

29. Refit

output shaft and housing.

30. Rcfit the diffcrential lock actuator assembly

NOTE: If a replacement differential unit is being
fitted, carry out the ‘Differential hearing pre-load

check’, described in ‘Speedometer drive housing

-

Overhaul’.

Assemble differential

CAUTION: It is essential that during the following

assembly all components are well lubricated with new oil
of the correct grade.

20.

Fit a sidc gear into the

casing.

21.

a

side gear into the front casing.

Fit the bevel pinions, thrust washers and

shafts into the front casing.

23.

Fit

casing to

front casing. Tighten the

bolts evenly

in sequence to

correct torquc. Use

Loctite 275 on threads.

24. Offer the low gear to the differential casing.
25. Align the fixing holes and fit

the

bolts

in

sequence to the correct torque.

Loctite

26.

Fit the roller bearings and refit the diffcrential

REMOVE AND OVERHAUL TRANSFER GEAR
LEVER AND CROSS-SHAFT

1.

Remove the

top

2. Slacken the selector finger pinch bolt.
3 . Drive out the retaining pin, gear lever to cross-

4.

Withdraw the gear lever.
Withdraw the cross-shaft and spacer.

6.

Lift out the selector finger.

7.

Remove the retaining plates.

8. Withdraw the scaling rings.

shaft.

Assemble gear lever and cross-shaft

9. Position the selector finger in

t h e

gearbox.

Fit the cross-shaft and spacing collar and

the selector finger.

side of the gearbox.

11.

Fit the sealing ring and retaining plate at the

R . H .

12. Fit

the gear lever and retaining

pin.

NOTE:

If the differential case or bearings have been

replaced, carry out the ‘Differential bearing
load check’.

44

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