Defender (1993+). Instruction - page 43
7.
Clean and examine all components and renew
where necessary.
8.
Assemble above parts in reverse order using
multi-purpose grease on gear lever.
NOTE: Ensure spring loaded pad is properly
located and that the lever is fitted to the housing
with the pad on the opposite side to the bias
spring. Leave bias spring adjusting screws slack
until assembly
of gearbox.
Remote gear lever housing.
1.
Release socket headed screw
to
remove
2. Remove circlip to release seating from
3.
Remove fifth gear locknut and stud.
trunnion.
trunnion.
3.
Drive-out roll pin to remove bias spring.
4.
Remove reverse gear plunger and shim.
4.
Remove gear lever extension from lower gear
lever.
5. Remove bolt and special washer
to
remove
lower gear lever.
WARNING: Hold the nylon spring loaded pad
while removing the lever to prevent
it
causing
personal injury.
6.
Remove gear selector housing from remote
housing.
5. Remove fifth gear
spool guide.
6. Remove blanking plug.
7. Drift-out roll pin securing quadrant to shaft.
8.
Withdraw selector shaft through hole.
9.
Remove selector shaft
“O”
ring.
10.
Remove circlip to release rollers and
pin
from
quadrant.
11.
Clean and examine all components and renew
where necessary.
12. Assemble housing
by
first fitting
“O”
ring
to
shaft.
13.
Fit quadrant and secure with
roll pin.
14.
Fit rollers and secure with circlip.
15. Fit fifth gear spool retainer and apply Loctite
290 to bolt threads.
16. Apply Loctite 290
to
reverse switch threads.
17.
Fit seating to trunnion and secure with circlip.
18.
Fit trunnion
to shaft and apply Loctite
to
retaining screw threads.
19. Fit reverse gear plunger and original shims.
20.
Fit fifth gear stud stop and locknut.
21.
Fit new
bucker plug with Hylomar PL 32.
22. Fit gear selector housing
to remote housing.
LT77S
MANUAL GEARBOX
GEAR SELECTOR HOUSING -
MAIN GEARBOX
1. Gear selector housing
14. Reverse gear plunger
2. Gasket
15. Gear lever seating
3. Roll pin
16. Trunnion
4. Bias spring
17. Circlip
5. Gear lever retaining screw and washer
18. Trunnion retaining screw
6. Selector housing screws
19. ' 0 ring
7. Gear lever
20. Selector shaft
8. Nylon pad and spring
21. Quadrant
9. Gear lever extension
22. Roll pin
10. Remote housing
23. Rollers
11. Gasket
24. Pin
12. Fifth gear spool guide
25. Blanking plug
13. Fifth gear stop screw and lock nut
REISSUED:
FEB
1993
15
LT77S
MANUAL GEARBOX
Reverse gear plunger assembly.
NOTE:
Assemble
the
housing
using
1. Remove plug spring and ball.
2. Remove circlip to release plunger and spring.
9. Fit internal and external " O " rings to fork
3. Clean and examine components.
assembly.
4. Assemble
plunger
and
spring
with
10. Fit detent spring.
multi-purpose grease and secure with circlip.
11. Fit "O" rings to end cover and fit to short end
5. Lubricate and fit detent ball and spring with
of cross shaft.
light oil. Apply Loctite 290 to plug threads and
12. Insert shaft into fork and secure end cover
fit.
with screws.
6. Check that plunger returns when depressed.
13. Fit Nylon seat, groove downwards, to gear
lever.
14. Fit gear lever and seat to cross shaft and
secure with circlip.
15. Fit bushes to gear lever and secure with
clevis pin and split pin.
multi-purpose grease on all moving parts.
Transfer gear housing.
1. Remove the four screws and remove gaiter
assembly.
2. Disconnect the gear lever from selector fork.
3. Retrieve the non metallic bushes.
4. Remove circlip to release ball and seat and
withdraw gear lever.
5. Remove screws from end cover to withdraw
cover and cross shaft.
6. Remove selector fork.
7. Remove detent spring and plate.
8. Clean and examine all parts and renew where
necessary.
16
REISSUED:
FEB
1993