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.
.
..
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90.110 130
DEFENDER
GEARBOX
WORKSHOP MANUAL SUPPLEMENT
Publication Number SLR 621 EN WS 2
Land Rover
Lode Lane
Published by the
Technical Publications Department of
Solihull
West Midlands, 892 8NW
England
Copyright Land Rover 1991
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37.MANUAL GEARBOX
.....
......
.....
. . . . .
. . . .
.....
.
....
CONTENTS
Page
OVERHAUL
DISMANTLE .....................................................................................................
GEAR SELECTOR HOUSING ..........................................................................
EXTENSION HOUSING....................................................................................
MAINSHAFT AND LAYSHAFT FIFTH GEARS ..................................................
REVERSE SHAFT, LAYSHAFT AND MAINSHAFT...........................................
DISMANTLE MAINSHAFT ................................................................................
GEARBOX CASINGS AND OIL PUMP .............................................................
GEAR CHANGE HOUSING ............................................................................
GEAR SELECTOR HOUSING ........................................................................
SYNCHROMESH ASSEMBLIES ....................................................................
CHECKING BAULK RING CLEARANCES ......................................................
INPUT SHAFT ................................................................................................
MAINSHAFT ...................................................................................................
MAINSHAFT GEAR END FLOAT CHECKS ....................................................
ASSEMBLING MAINSHAFT ...........................................................................
LAYSHAFT .....................................................................................................
REVERSE GEAR AND SHAFT ......................................................................
SELECTORS..................................................................................................
ASSEMBLING GEARBOX SHAFTS TO CENTRE PLATE ..............................
FITTING GEARBOX CASING .........................................................................
FITTING FIFTH GEAR ....................................................................................
FIFTH GEAR SELECTOR FORK ASSEMBLY ................................................
EXTENSION CASE ........................................................................................
2
3
5
7
8
17
18
18
19
21
23
23
24
25
27
28
30
31
32
32
33
35
35
INPUT-MAINSHAFT BEARING ADJUSTMENT ..............................................
LAYSHAFT BEARING ADJUSTMENT ............................................................
GEAR LEVER AND REMOTE HOUSING ASSEMBLY ...................................
BELL HOUSING
BELL HOUSING
-
-
FOUR CYLINDER ENGINE ...............................................
V8 ENGINE .......................................................................
SPECIFICATIONS. TORQUE
DATA ...............................................................................................................
TORQUE VALUES ...........................................................................................
1
1
SERVICE TOOLS
SERVICE TOOLS .............................................................................................
1
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37 MANUAL GEARBOX
CONTENTS
Page
LOCALLY MANUFACTURED TOOLS ..............................................................
GEARS AND SHAFTS .....................................................................................
3
5
GEARBOX
.........................................................................................
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MANUAL GEARBOX
DISMANTLE
Bell housing
-
four cylinder engine
1. Remove transfer box, drain
exterior.
and clean
2. If fitted, clutch release bearing clip.
3. Remove clutch release assembly.
4. Remove one pivot post bolt, slacken the other
and move post aside.
GEAR SELECTOR HOUSING
Remove six bolts and withdraw bell housing.
1. Remove four bolts and remove main gearbox
selector housing.
2. Remove transfer box housing.
Remove remaining bolts and remove remote
housing.
Bell housing V8 engine
-
Remove clutch release bearing.
2. Remove screw and spring clip and remove
release lever.
Remove
"
C
"
clip from pivot post.
4. Remove six bolts and bell housing.
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MANUALGEARBOX
DEFENDER
4. Drive out quadrant roll pin.
2. Using service tool 18G 705 and 18G 705-1A
Move selector shaft forward to remove
quadrant.
withdraw the oil seal collar.
18G 705
/U
5
3. Remove the fifth gear extension housing.
4. Secure the centre plate to the gearcase with
two bolts.
EXTENSION HOUSING
.
8
x
1. Remove snap ring retaining oil seal collar.
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2
OVERHAUL
MANUAL GEARBOX
.:
retaining mainshaft fifth gear
synchromesh.
tool 18G 1400
MAINSHAFT AND LAYSHAFT FIFTH GEARS
-
1
and
1400 as
illustrated.
mainshaft
2. Remove oil pump drive shaft.
3. clips from selector fork.
ring.
"
E"
4. Remove fifth gear selector
5. Remove selector fork bracket.
. .
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MANUALGEARBOX
DEFENDER
11. Remove fifth gear synchromesh.
3. Invert gear case and locate studs in workstand
holes.
12. Remove layshaft fifth gear using special tools
18G 705 and 18G
4. Remove selector shaft spool retainer.
Main gear case.
1. Secure reverse shaft retainer, manufactured
to centre plate.
Fit studs, manufactured
to gear case.
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4
OVERHAUL
MANUALGEARBOX
DEFENDER
Remove input shaft and fourth gear baulk ring.
6. Remove layshaft by tilting, as illustrated and
lifting mainshaft.
5
ST
U
7. Unscrew plug and remove spring and outboard
detent ball.
8. Align fifth gear selector pin with centre plate
slot.
Collect inboard detent ball and spring from
centre plate.
9. Remove mainshaft, gears, selectors and forks.
10. Remove selector fork assembly from gears.
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MANUAL GEARBOX
.
,
.
.
..
,
... .,....,
12. Using extractor tool 18G 705 and collets
705-7, withdraw layshaft bearings.
.
DISMANTLE MAINSHAFT
1. Remove circlip retaining first gear assembly.
4. With MS 47 press first gear assembly from
mainshaft.
ST
4
Remove taper bearing, bush, needle bearing,
first gear spacer, cone, inner and outer baulk
rings.
3. Remove circlip to release first and second gear
synchromesh assembly.
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MANUALGEARBOX
DEFENDER
5. Remove first and second synchromesh baulk
rings.
GEARBOX CASINGS AND OIL PUMP
6. Using MS 47 and support bars under second
gear, press offpilot bearing, third, fourth
synchromesh second and third gear assembly.
Degrease and clean all components and discard
gaskets and seals.
Gearbox casing
1. Remove mainshaft and layshaft bearing tracks.
2. Remove plastic scoop from inside the casing.
3. Inspect case for damage, cracks and stripped
7. Remove washer, third, fourth synchromesh,
third gear baulk ring, split needle rollers, bush,
needle bearing and second gear.
8. Remove snap ring, spacer, second gear cone
and circlip.
threads.
Fit a new scoop with scoop side towards top of
casing.
Front cover
1. Remove oil seal from cover. Do not fit a new
seal at this stage
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MANUAL GEARBOX
3. Check oil pick up pipe for obstruction but do
not remove.
Centre plate
4. Remove drain plug assembly. Clean and renew
filter and washers if necessary.
Renew oil seal.
1. Remove bearing tracks.
2. Inspect for damage and selector rail bore for
wear.
6. Renew Ferrobestos bush.
3. Temporally fit reverse shaft gear and lever and
check clearance between slipper and lever
WARNING: This bush contains
not attempt to clean it. see
INTRODUCTION, Information, Poisonous
substances.
does not exceed
(0.008 in).
7. Fit new bush with drain holes towards bottom of
casing.
CAUTION: If drain holes are not
positioned correctly oil may build up
behind oil seal and cause a leak.
Extension case
1. Examine for damage to threads and machined
faces.
2. Remove oil pump cover, inspect gears and
housing and renew if required.
8. If extension housing is being renewed transfer
grub screw to new housing. Apply Loctite to
threads.
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MANUALGEARBOX
DEFENDER
9. Fit oil seal to housing, lip side leading, using
18G 1422. Apply SAE 40 oil to lip.
3. Drive-out roll pin to remove bias spring.
4. Remove gear lever extension from lower gear
lever.
Remove bolt and special washer to remove
lower gear lever.
WARNING: Hold the nylon spring loaded
pad while removing the
causing personal injury.
to prevent it
6. Remove gear selector housing from remote
housing.
10. Assemble gears to oil pump and fit cover.
GEAR CHANGE HOUSING
1. With a length of tube, release the bias spring
from adjusting screws.
2. Remove bias spring adjusting screws.
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OVERHAUL
MANUAL GEARBOX
,
10. Remove circlip to release rollers and pin from
quadrant.
7. Clean and examine all components and renew
where necessary.
8. Assemble above parts 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
trunnion.
2. Remove circlip to release seating from trunnion.
3. Remove fifth gear locknut and stud.
4. Remove reverse gear plunger and shim.
I
11. Clean and examine all components and renew
where necessary.
12. Assemble housing by first fitting
shaft.
"
0
"
ring to
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 bucket plug with Hylomar PL 32.
22. Fit gear selector housing to remote housing.
5. Remove fifth gear spool guide.
6. Remove blanking plug.
7. Drift
8. With selector
9. Remove selector shaft
-
out roll pin securing quadrant to shaft.
hole.
"
0
"
ring.
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DEFENDER
MANUAL GEARBOX
.
GEAR SELECTOR HOUSING
Reverse gear
lever
16. Trunnion
selector housing
2. Gasket
Roll pin
ring
Selector
Quadrant
Roll
23. Rollers
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MANUAL GEARBOX
Reverse gear plunger assembly.
NOTE:Assemble the housing using
grease on
moving parts.
1. Remove plug spring and ball.
2. Remove circlip to release plunger and spring.
3. Clean and examine components.
9. Fit internal and external
assembly.
"0"
rings to fork
4. Assemble plunger and spring with multi
-purpose
10. Fit detent spring.
grease and secure with circlip.
11. Fit
rings to end cover and fit to short end
5. Lubricate and fit detent ball and spring with light
oil. Apply Loctite 290 to plug threads and fit.
6. Check that plunger returns when depressed.
of cross shaft.
12. Insert shaft into fork and secure end cover with
screws.
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
pin and split pin.
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 ail parts and renew where
necessary.
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MANUALGEARBOX
DEFENDER
12
15
I
17
ST
1. Gaiter retaining screw
Gaiter.
-
off,
11. Cross shaft.
12. Gear lever.
3. Gaiter support plate.
4. Gate plate.
5. Gasket.
13. Gear change housing.
14. Non-mettalic bushes.
15. Counter sunk screws.
16. End cover.
6. Split pin.
7. Clivis pin.
8. Circlip retaining Nylon seat.
9. Gear lever ball.
17. Detent spring and plate.
18. Selector fork.
19.
"
0
"
rings.
10. Nylon seat.
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MANUAL GEARBOX
SYNCHROMESH ASSEMBLIES
Third
-fourth and fifth gear synchromesh.
NOTE: the above assemblies are the
same except that fifth gear synchromesh
has a retainer plate.
1. Mark relationship of inner and outer members.
2. Remove wire clip from both sides of assembly.
7. Examine the dog teeth on all gears for wear and
damage.
NOTE:
good condition.
shows a tooth in
shows the
rounded corners of a worn tooth.
3. Remove slippers and separate the two
members.
4. Examine all parts for damage and wear
including wire clips for tension.
5. Check no radial movement exists between inner
members and mainshaft splines. (except fifth
gear synchromesh).
6. Examine inner and outer splines for wear.
OVERHAUL 15
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MANUALGEARBOX
DEFENDER
First-second synchromesh
12. Fit the slippers and secure with a spring each
of the synchromesh.
8. Repeat instructions
synchromesh.
Examine step in each of outer splines.
10. Check that the step on both sides of the
internal splines are sharp not rounded.
for third-fourth
NOTE: The hooked end of each spring
must locate in the same slipper with the
free ends running in opposite directions
and resting against the remaining slippers.
NOTE: this applies only to splines on
selector groove side of member.
13. Assemble third-fourth and fifth gear
synchromesh components as in instruction 12.
11. Fit inner member to outer so that the wide
splines of inner member are under the spur
gear teeth.
NOTE: The back plate for fifth gear is
fitted to the rear of the assembly with the
single tag locating in
member.
a
slot in the inner
11
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OVERHAUL
MANUAL GEARBOX
Third gear
CHECKING BAULK RING CLEARANCES
Check clearance of all baulk rings and gears by
pressing the baulk ring against the gear and
measuring the gap. The minimum clearance should
be
First gear
ST
Fourth gear
second gear
ST32 26M
Fifth gear
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OVERHAUL 17
MANUALGEARBOX
DEFENDER
INPUT SHAFT
6. Using Press MS47,Collets 18G 478and
adaptor 18G 47 fit a new taper bearing.
1. Examine the gear and dog teeth for wear and
damage.
2. Polish oil seal track if necessary.
3. Using 18G 284AAH and 18G 284remove pilot
bearing track.
\
.. .
,
.
4. Using 18G 47BAand MS 47remove taper
bearing.
NOTE: ensure that the bearing is
supported by the lip inside 18G 47 BA.
MAINSHAFT
1. Examine bearing journals for wear and scores.
2. Check condition of circlip grooves.
3. Examine splines for wear and damage.
4.Use an air line to check that the main oil feed
from the pump is clear and feed to spigot
bearing.
5. Check oil feed holes to roller bearings are clear.
3
5. Support the shaft under MS 47and press in
a
new track.
M
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MANUAL GEARBOX
MAINSHAFT GEAR END FLOAT CHECKS
Third gear end-float.
1. Hold mainshaft in vice front end downwards.
1. Fit needle roller to third gear.
2. Fit front circlip for first
3. Fit second gear cone.
4. Fit spacer.
-second synchromesh.
2. fit third gear bush to third gear.
3. Place gear on flat surface, bush flange
downwards, and with
a
straight edge across
5. Fit snap ring.
gear check clearance between straight edge
and gear. Not to exceed
M
Second gear end-float.
First gear bush end-float.
1. Fit needle roller and second gear
2. Fit third gear bush.
1. Invert mainshaft rear end uppermost.
2. Fit inner and outer second gear baulk rings.
3. Check clearance between second gear and
bush flange. Not to exceed
4. Remove above components.
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OVERHAUL
19
MANUALGEARBOX
DEFENDER
3. Fit first
uppermost.
4. Fit circlip.
-
second synchromesh hub, fork groove
8. Fit first gear bush.
9. Fit dummy bearing.
10. Fit circlip.
11.
Check clearance between dummy bearing and
bush. Not to exceed
12.
Remove circlip, dummy bearing and bush.
M
9
First-second synchromesh assembly
8
7
ST3
I
I
Selective first gear bush
Part number
Thickness
30,955131,005
31,005131,055
31
Check first gear to bush end float.
1.
,105/31,155
-
Fit roller bearing and bush to first gear.
T3257M
2. Place bush flange side downwards on a raised
block on a flat surface.
NOTE:the block should be approximately
the same diameter as the bush flange so
that the gear is suspended and does not
rest on the flat surface.
Fit first gear inner and outer baulk ring.
Fit cone.
7. Fit spacer.
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MANUAL GEARBOX
3. Place straight edge across gear and check
clearance between gear and straight
to exceed
3
1
4. Fit the taper bearing to mainshaft using MS 47,
collets 18G 47 BA and adaptor 18G 47
ASSEMBLING MAINSHAFT
With the first-second synchromesh hub and
spacer in position, assemble the rear end of the
shaft.
2. Fit the roller bearing and bush to first gear.
3. Fit first gear to mainshaft.
First gear assembly
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OVERHAUL
MANUAL GEARBOX
DEFENDER
7.
mainshaft in
and fit second gear needle roller, and second
gear.
rear end downwards
CAUTION: Ensure that the slots in the
baulk ring align with the synchromesh
slippers while pressing on the bearing.
8. Fit third gear bush.
9. Fit third gear needle rollers.
10. Fit third gear.
5. Invert mainshaft and press assembly back
against circlip.
11. Fit third gear baulk ring.
MS
5
NOTE: Instruction
5
is necessary since it
is probable that when pressing on the
bearing it will have clamped the first gear
bush preventing it from turning.
6. Reposition mainshaft in vice and using a screw
driver blade check that the first gear bush is
free to turn.
Third-fourth synchomesh assembly
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22
OVERHAUL
MANUAL GEARBOX
12. Fit third-fourth gear synchromesh hub.
LAYSHAFT
13. Using MS 47 with supports under first gear,
press the spigot bearing on to shaft.
1. Examine the layshaft for wear and damage.
Press bearings on to layshaft using MS 47 and
supporting bars.
-12
MS.47
REVERSE GEAR AND SHAFT
1. Remove one circlip from the idler gear and
remove bearings.
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OVERHAUL
MANUALGEARBOX
DEFENDER
.
SELECTORS
NOTE: One bearing cage is twisted in
manufacture. The twist causes the gear
to tilt on the shaft forcing the gear into
engagement. Renew bearings if worn or if the
gear jumps out of engagement.
1. Examine selector rail and pins for wear and
damage.
Examine first-second selector fork for wear
2.
cracks and damage.
NOTE:The the selector rail and fork is
only supplied as a complete assembly.
Examine third-fourth selector fork for wear,
cracks and damage.
Examine fifth gear selector fork, pads and pivot
pins.
4.
Examine interlock spools for wear and damage.
5.
.
.
.
....
.
1
2. Fit the bearings either way round and secure
with the circlip.
3. Check condition of idler gear and mating teeth
on layshaft and synchromesh outer member.
4
Renew retaining
if distorted.
6.
4. Examine idler shaft for wear. scores and oittina.
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MANUAL GEARBOX
..
Assembling selectors.
ASSEMBLING GEARBOX SHAFTS TO CENTRE
PLATE
7. Rest first
bench and locate pin in jaw of fork.
8. Fit interlock spool and third fourth fork and
engage spool in jaw of fork.
-second fork and shaft assembly on
Fitting gears to centre plate
-
1. Secure centre plate to workstand, fit bearing
tracks and inboard detent ball and spring.
8
7
9. Slide spool and fork towards first
-
second
selector until slot in spool locates over pin
keeping the spool engaged in third-fourth fork
jaw.
2. Check both synchromesh units are in neutral
and fit selector shaft assembly.
3. Fit mainshaft and selectors to centre plate and
align pin with slot in plate.
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MANUALGEARBOX
DEFENDER
Fit layshaft While lifting mainshaft to clear
layshaft rear bearing.
10. Secure reverse shaft
manufactured tool
"
A".
5. Turn selector shaft and interlock spool to allow
reverse lever to engage spool flange.
6. Fit reverse lever to pivot post and secure with
pin and circlip.
11. Fit reverse gear thrust washer to shaft.
12. Fit fourth gear baulk ring.
13. Lubricate spigot bearing and fit input shaft.
14. Remove centre plate workstand
gasket.
and fit
7. Fit slipper pad to lever.
Fit reverse gear shaft, spacer and gear.
9. Fit slipper to reverse gear and ensure roll pin in
shaft engages in slot in centre plate.
'
I
10
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26 OVERHAUL
MANUAL GEARBOX
>
I
FITTING GEARBOX CASING
1. Turn selector shaft and spool to neutral
position.
2. Fit out
-
board detent ball and
and secure
with plug.
not use force to fit retainer.
2
Provided the spool has not been
disturbed the retainer will slide into
position. If not, remove the gear case and
reposition spool or shaft.
3. Fit guide studs to
correctly fitted.
4. Without using force, fit gearcase.
and check oil scoop
I
S
7. Remove detent plug, apply Loctite 290 or
Hylomar PL 32 to thread, refit and stake.
8. Fit layshaft and input shaft bearing tracks.
NOTE: Ensure that the centre plate
dowels and selector shaft are properly
located.
5. Secure centre plate and gearcase to workstand
with two bolts.
8
x
6. Apply PL 32 to joint face and bolt threads and
fit spool retainer.
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OVERHAUL
27
MANUALGEARBOX
DEFENDER
FITTING FIFTH GEAR
4. Fit a new stake nut but do not tighten.
5. Fit gear assembly to mainshaft.
CAUTION: Since the fifth gear is a tight
fit on the layshaft, the force, when
pressing the gear, must not be transfered
to the layshaft front bearing.
packing disc should be made to the dimensions
given to absorb the force. The plate also retains
the input shaft bearing outer track.
1. Secure the plate with two
bolts. Insert
disc between plate and layshaft.
Release and invert gearbox and remove reverse
shaft retainer plate.
3. With the extraction groove uppermost, drive fifth
gear on to layshaft using 18G 1422.
I
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OVERHAUL
MANUAL GEARBOX
........
.
.
..
6. Press fifth gear synchromesh assembly to
Part number
Thickness
mainshaft using 18G 1431.
FRC 5284
FRC 5286
FRC 5288
FRC 5290
FRC 5292
FRC 5294
FRC 5296
FRC 5298
FRC 5300
FRC 5302
CAUTION: Before pressing the assembly
fully home, ensure that the slipper pads
locate in the baulk ring slots.
5.64
7. Fit the thinnest washer and secure with circlip.
8. Measure clearance between circlip and washer,
9. Tighten layshaft stake nut using 18G 1205.
CAUTION: The practice of locking gears
to provide
not acceptable due to high torque figure
required.
a
restraint to tighten the nut is
NOTE: Only limited movement of the
synchromesh inner member on the
main
clearance is
-
shaft is permissable. The maximum
to to
and to achieve this the following
selective washers are available.
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MANUAL GEARBOX
DEFENDER
FIFTH GEAR SELECTOR FORK ASSEMBLY
10. Secure tool
"
A
"
to gear and gear case and
using a suitable torque wrench tighten the nut
to the correct torque.
1. Fit fifth gear selector fork bracket.
Fit the fifth gear spool long end towards centre
plate.
Using a round nose punch, form the collar into
the layshaft slots.
3. Fit slippers to selector fork.
4. Fit fork to synchromesh and secure with pins
and
"
E
"
clips.
NOTE: Before fitting pins and clips cover
holes in centre plate to prevent them
falling into casing.
5. Engage tongue of spool in selector fork.
6. Fit oil pump drive to layshaft.
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MANUAL GEARBOX
.
.
.
......f.
,
..
.
EXTENSION CASE
1. Release centre plate from workstand and fit
gasket on joint face.
2. Fit extension case while aligning oil pick-up
pipe. Remove guide studs and secure to main
case.
NOTE: Do not use force, if necessary
remove case and re-align oil pump drive
if case does not fit first time.
CAUTION: To protect
"
0
"
ring while
fitting, cover mainshaft splines with
smooth tape.
3. Fit
"
0
"
ring to mainshaft groove.
'3221
M
U
7
4. Fit
"
0
"
ring collar to mainshaft using 18G 1431
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OVERHAUL
MANUALGEARBOX
DEFENDER
INPUT
-
MAINSHAFT BEARING ADJUSTMENT
Mainshaft selective washers
Part number
1. Turn gearbox over with input shaft uppermost.
Remove layshaft support plate.
FRC 4327
FRC 4329
FRC 4331
FRC 4333
FRC 4335
FRC 4337
FRC 4339
FRC 4341
FRC 4343
FRC 4345
FRC 4347
FRC 4349
FRC 4351
FRC 4353
NOTE: Correct shimming of the input
shaft bearing is vital to ensure that the
mainshaft assembly has the design
intended end float, and the bearings are not
pre-loaded.
2. Measure the thickness of a new front cover
gasket.
3. Place the original shim on mainshaft bearing
and finger tighten the bolts.
4. Measure the clearance between front cover and
gearcase with two feeler gauges.
2.35
FRC 4355
FRC 4357
FRC 4359
FRC 4361
FRC 4363
FRC 4365
FRC 4367
FRC 4369
LAYSHAFT BEARING ADJUSTMENT
Place original selective washer on layshaft
bearing, fit front cover without gasket, and
finger tighten bolts.
1.
Measure clearance, with two feeler gauges,
2.
between cover and gearcase. Select
a
shim
that will provide a clearance equal to the
thickness of the gasket that was selected and
measured when calculating the adjustment of
the input and mainshaft bearing.
5. If required, change the selective washer to
provide a clearance of
to
(0.001 to
less than the gasket
thickness.
NOTE: This will ensure that when the
gasket and cover is fitted to the correct
torque, the input and mainshaft bearings
will have no pre
-
load
more than
end float.
6. Remove front cover and keep gasket and
selective washer together.
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32 OVERHAUL
MANUAL GEARBOX
NOTE: This will ensure zero layshaft
bearing end float and not more than
GEAR LEVER AND REMOTE HOUSING
ASSEMBLY
(0.001 in) pre-load once the
cover and gasket are fitted and bolts correctly
1. Fit quadrant to selector shaft with new roll pin.
NOTE: Push shaft forward, fit quadrant
so ledge is to the left viewing box
rear. Return shaft to neutral position.
3. Remove cover and selected washer and fit new
seal,
towards gearcase.
4. Fit mainshaft and layshaft selected washers and
gasket.
4
2. With a new gasket, fit remote housing locating
over dowels.
5. Wrap protective tape round input shaft splines.
Apply Hylomar PL 32 to bolt threads and secure
cover.
NOTE: Ensure rollers locate in quadrant
fork.
3. Fit transfer gear change housing.
Reverse gear plunger adjustment.
Layshaft selective washers.
Part number
1. Fit plunger with original shims and tighten bolts.
2. Slacken locknut, turn adjuster screw so that
FTC 0262
FTC 0264
FTC 0266
FTC 0268
FTC 0270
FTC 0272
FTC 0274
FTC 0276
FTC 0278
FTC 0280
FTC 0282
FTC 0284
FTC 0286
FTC 0288
FTC 0290
FTC 0292
FTC 0294
0296
dimension
in). Tighten locknut.
"
A
"
is approximately 12
-
A-(
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DEFENDER
MANUALGEARBOX
NOTE: If necessary, final adjustment can
be made in vehicle. To increase
load turn screw clockwise or
Bias spring adjustment
NOTE: The purpose of this adjustment is
to set both bolts so that the bias spring
legs apply equal pressure on both ends
of the gear lever cross pin when third or fourth
gear is engaged. This will ensure that when the
lever is in neutral, the gear change mechanism
is automatically aligned for third or fourth gear
selection.
anti
-
clockwise to reduce load.
Fifth gear stop screw adjustment.
1. Adjust screw to protrude from housing the
distance across corners of locknut.
NOTE: This is only an approximate
setting which will limit travel of selector
yoke but will allow fifth gear to be
selected.
1. Select fourth gear and
the cross pins.
2. Turn adjustment bolts until heads touch spring
legs.
both spring legs over
3. Apply light pressure to gear lever to the right
and adjust left hand bolt.
NOTE: Clearance between spring leg and
bolt
(0.002 in.) using feeler
gauge.
4. Move lever to left and adjust right hand bolt to
clearance.
5. Tighten locknuts.
2. Select fifth gear. While applying light pressure
to gear lever towards right, turn screw
clockwise until it contacts yoke. Turn screw half
a
turn
clockwise and tighten nut.
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MANUAL GEARBOX
BELL HOUSING
-
FOUR CYLINDER ENGINE
BELL HOUSING
-
V8 ENGINE
Fit bellhousing locating over hollow dowels and
secure with bolts.
1. Fit bell housing locating on hollow dowels.
NOTE: Fit the 12
x
bolts through
NOTE: Fit the 12
dowels and 12
remaining positions.
x
30
45
bolts through
bolts in
dowels and 12
positions.
x
bolts in remaining
x
2. Apply molybdenum disulphide grease to pivot
post, release lever, socket and push rod. Not
the bearing guide.
2. Secure pivot post.
3. Apply molybdenum disulphide grease to pivot
post, lever pads and pins.
4. Assemble pads to lever and lever to bearing
and fit assembly to pivot post.
Fit 'C' washer to pivot post.
3.
4.
Fit spring clip to lever and fit lever to pivot post.
NOTE: Position spring clip behind 'C'
washer and tighten screw.
5. Fit staple to release assembly, short leg to
lever.
NOTE: The staple is an aid to assembly
only which may become dislodged or
lost in service without detriment.
Fit bearing and retain with plastic staple.
4
4
4
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MANUAL GEARBOX
DATA
Reverse lever and slipper pad clearance
Reverse gear plunger operating load ................................
Synchromesh assemblies push through load
Clearance between baulk rings and gears ........................
Fifth gear end float ............................................................
Third gear end float
45 to 55
8,2 to 10 kgf
0,020
0,020
0,020
0,075
Second gear end float
First gear bush end float
First gear end float
Fifth gear synchromesh end float
0,005 to 0,055
TORQUE VALUES
NOTE: Torque wrenches should be
regularly checked for accuracy to ensure
that all fixings are tightened to the
correct torque.
7
7
7
7
7
22
22
22
22
-
-
-
-
-
-
-
-
-
10
10
10
10
10
28
28
28
28
Oil pump to extension case
Clip clutch release lever
Spool retainer to gearcase
Spool guide to remote housing
Extension case to gearcase
Pivot plate, clutch release
Remote housing to gearcase
Gear lever housing to remote housing
Guide, clutch release sleeve
Slave cylinder to bell housing
Front cover to gearcase
Fifth gear support bracket bolts
Plunger housing to remote housing
Gear lever retainer
Lower gear lever to extension nut
Reverse lever pivot post nut
Clutch housing to gearbox bolts
Plug, detent spring and ball
Oil drain plug
22 28
22
22
22
7
-
-
-
-
-
-
28
28
28
10
47
28
80
28
54
80
35
16
231
10
40
22
65
22
47
65
25
14
204
7
-
-
-
-
-
-
-
-
Oil filter plug
Oil filler
Breather
-
level plug
Fifth gear layshaft stake nut
Bottom cover to clutch housing
SPECIFICATIONS, TORQUE
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MANUAL GEARBOX
SERVICE TOOLS
NOTE: Where the use of special tools is
specified, only these tools should be
used to avoid the possibility of personal
injury and or damage to components.
18G 1400
Remover synchromesh hub and
gear cluster
18G.7400
-1
18G 705
Puller, bearing remover
8G 1400
-1
Adaptor mainshaft fifth gear
8G 705-1A
Adaptor for mainshaft oil seal
track and layshaft fifth gear
MS47
47
Hand press
8G 705-7
Adaptor for layshaft bearings
Adaptor input shaft bearing
SERVICE TOOLS
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MANUAL GEARBOX
DEFENDER
18G.1431
18G
Conversion kit
18G 1431
Mainshaft rear oil seal replacer
18G 284
Impulse extractor
18G 1205
Flange holder
8G
Adaptor for input shaft pilot
bearing track
8G 1422
Mainshaft rear oil seal replacer
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2
MANUAL GEARBOX
.
-
-
LOCALLY MANUFACTURED TOOLS
Tool
Mild steel dummy centre bearing for the
selection of first gear bush.
In addition to the special service tools, the following
tools can be locally made to assist the dismantling
and assembly of the gearbox. The following overhaul
procedure is based upon the assumption that these
tools are available.
C
0.10
Tool 'A'. Dual purpose tool. Reverse shaft retainer to
prevent the shaft falling out when the gearbox in
inverted. Also, a layshaft fifth gear retainer to hold
the fifth gear whilst releasing stake nut. Use 5mm
mild steel to manufacture the tool. When using the
tool for the layshaft nut, a suitable spacer is required
diameter
long, with an 8mm diameter
clearance hole.
+
-
154M
Tool 'D'. Layshaft support plate is fitted with two 8
x
bolts and washers to the front of the gearbox
case. It also supports the input shaft bearing outer
track.
D
Tool
Four pilot studs with an
thread for
locating in the four counter sunk blind holes in the
workstand.
B
.
ST 2155M
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SERVICE TOOLS
MANUALGEARBOX
DEFENDER
Tool 'E'. Workstand for securely locating the gearbox
The four counter sunk blind holes marked 'B' should
during overhaul. Manufacture from
angle iron. The single hole marked 'A' should be
drilled through the material with a drill.
x
also be made with a
drill, but must not be
drilled through the material.
I
64mm
I
1
52mm
I
I
I
I
I
I
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SERVICE TOOLS
MANUAL GEARBOX
.
.
.
...
.
...
.
....
,
Snap ring retaining second gear cone and
52.
GEARS AND SHAFTS
spacer.
Spacer.
54. Snap ring.
1.
Third
-
fourth selector fork.
2. Interlock spool.
3. First
-
-
second fork and selector rail assembly.
second synchromesh.
55. Reverse idler gear.
4.
Thrust washer.
First
56.
57. Snap ring.
Fifth gear spool.
5. First gear synchromesh outer baulk ring.
6. First gear synchromesh inner baulk ring.
58.
7.
Cone.
Thrust washer.
First gear.
8.
9.
Needle roller bearings.
10.
11. First gear selective bush.
12.
Centre taper roller bearing.
13. Circlip.
14.
15.
16.
17.
Thrust washer.
Fifth gear.
Fifth gear baulk ring.
Fifth gear synchromesh.
.
...
18. Fifth gear synchromesh back plate.
19. Fifth gear synchromesh selective washer.
Circlip.
20.
21.
"
0
"
ring.
22. Oil seal collar.
Snap ring.
23.
24. Fourth gear baulk ring.
Pilot taper bearing.
25.
26. Spacer.
27. Third fourth synchromesh.
-
28. Third gear baulk ring.
29. Third gear.
30. Third gear bush.
31.
Second gear.
32. Thrust washer.
33. Cone.
34. Second gear synchromesh inner baulk ring.
Second gear synchromesh outer baulk ring.
Mainshaft.
35.
36.
,
,
Input shaft bearing track and selective washer.
38. Input shaft.
39. Input shaft taper bearing.
40.Fourth gear.
41. Selective shim.
42. Taper bearing.
43. Layshaft fourth gear.
44. Layshaft third gear.
45. Layshaft second gear.
46. Layshaft reverse gear.
47.
48.
Layshaft first gear.
Taper bearing.
49. Layshaft fifth gear.
gear retaining stake nut.
Circlips retaining first gear and first
synchromesh.
-second gear
51.
SERVICE TOOLS
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I
MANUALGEARBOX
DEFENDER
M
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SERVICE TOOLS
MANUAL GEARBOX
,
GEARBOX CASING
14. Selector plug, detent ball and spring.
15. Gasket.
1. Front cover.
2. Front cover oil seal.
Fifth gear selector bracket.
17. Fifth gear selector fork.
18. Reverse gear shaft.
Front cover gasket.
4. Oil drain plug and washer.
5. Oil level plug.
Gearbox main casing.
7. Spool retainer.
8. Gasket.
9. Inboard detent ball and spring.
10. Reverse lever and slipper.
19. Oil pick-up pipe.
20. Oil pump drive shaft.
21. Oil pump gears and cover.
22. Fifth gear extension housing.
23. Fifth gear extension housing drain plug and
filter.
24. Ferrobestos bush.
11. Locating dowels
12. Reverse lever pivot post.
13. Centre plate.
-
centre plate to maincase.
25. Oil seal.
SERVICE TOOLS
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