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