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

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