Section CONTENTS

- .- .
y;. Number Page
' L .I.
I..

LT77 FIVE SPEED GEARBOX

37 LT230R TRANSFER GEARBOX

- Overhaul 20
Renew front output shaft oil seals 1 can be 18

* 37 LT95 FOUR SPEED GEARBOX AND TRANSFER BOX

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37 LTWLT230T MAIN GEARBOX AND TRANSFER BOX

- Remove 61
- Overhaul LT85 gearbox 62

37 I LT230T TRANSFER GEARBOX

- Remove from LT85 gearbox 86

- Overhaul 91

147I PROPELLER SHAFTS

51 REAR DIFFERENTIAL -NINETY HEAVY DUTY

51 REAR DIFFERENTIAL -NINETY

- Overhaul 16

FRONT DIFFERENTIAL - ONE TEN AND NINETY

-Overhaul 16

I
 INTRODUCTION

This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to
assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be
completed within the time stated in thc 'Repair Operation Times'.

The Manual has been produced in separate books; this allows the information to be distributed throughout the
specialist arcas of the modern service facility.

A table of contents in Book 1 lists the major components and systems together with the scction and book numbers.
The cover of each book details the sections contained within that book. Each section starts with a list of operations in
alphabetical order.

The title page of each book carries the part numbers required to order replacement books, binders or complete
Service Manuals. This can be done through the normal channels.

REFERENCES
References to the left- or right-hand side in the manual are made when viewing the vehicle from the rear. With the
engine and gearbox assembly rcmovcd, the water pump end of the enginc is referred to as the front.
To reduce repetition, operations covcrcd in this manual do not include reference to testing the vehicle after repair. It
*
(7:

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is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out
particularly where safety related items are conccrned. - 2 s

DIMENSIONS
The dimensions quoted are to design engineering spccification. Alternative u n i t equivalents, shown in brackets
following the dimensions, havc bccn converted from the original specification.
During thc pcriod of running-in from new, ccrtain adjustments may vary from the specification figurcs given in this
Manual. These adjustments will be re-set by t h e Distributor or Dealer at thc Aftcr Sales Service, and thercal'ter
should be maintained at the figures spccified in the Manual.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential that only Land Rover parts are used.
Attention is particularly drawn to the following points concerning rcpairs and the fitting of replacement parts and
accessories:
Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain
territories, legislation prohibits the fitting of parts not to the vehiclc manufacturer's specification. Torque wrench
setting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners
purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle g?-
"---
.. .
conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement
may be invalidated by the fitting of other than Land Rover parts.
All Land Rover parts havc the full backing of the Owners Service Statement.
Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts.

POISONOUS SUBSTANCES
Many liquids and other substances used in motor vehicles are poisonous and should under n o circumstances be
consumed and should as far as possible be kept away from open wounds. These substances among others include
antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled
safe!y. It 2!so oll!!iReS !he ather are2s of risk which m u t not be ignored.
This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of
your local Fire Officer.

GENERAL
Petrol/gasoline vapour I S highly flammable and in confined spaces is also very explosive and toxic.
When petroVgasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. I t can
readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is
potentially very dangerous.
II
 Always have a fire extinguisher containing FOAM CO2 GAS, or POWDER close at hand when handling or draining
fuel, or when dismantling fuel systems and in areas where fuel containers are stored.
Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system.
Whenever petroVgasoline is being handled, draincd or stored, or when fuel systems are being dismantled all forms of
ignition must be extinguishcd or removed, any head-lamps used must be flameproof and kept clear of spillage.

NO O N E SHOULD B E PERMITTED T O REPAIR COMPONENTS ASSOCIATED WITH PETROL!

GASOLINE WITHOUT FIRST HAVlNG H A D SPECIALIST TRAINING.

FUEL TANK DRAINING

WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED FROM ANY VEHICLE WHILST
IT IS STANDING OVER A PIT.

Draining or extracting petroligasoline from vehicle fuel tank must be carried out in a well ventilated area.
The receptacle used to contain the pctrol/gasoline must be more than adequate for t h e full amount or fuel to be
extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storagc area
which meets the requirements of local authority regulations.
WHEN PETROL/GASOLINE HAS BEEN EXTRACTED OR DRAINED FROM A FUEL TANK THE
PRECAUTIONS GOVERNING NAKED LIGHTS AND IGNITION SOURCES SHOULD BE MAINTAINED.

FUEL TANK REMOVAL

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On vehicles where the fuel line is secured to the fuel tank outlet by a spring steel clip, it is recommended that such
clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedure will avoid the
possibility of residual petrol fumes in the fuel tank being ignited when the clips are relcased.
As an added precaution fuel tanks should havc a PE'I'ROL/GASOLINE VAPOUR warning label attached to them
as soon as t h e y are rcmovcd from the vehicle.

FUEL TANK REPAIR

Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering
the tank SAFE, by usingone of the following methods:
STEAMING: With the filler cap and tank unit removed, empty the tank. Steam thc tank for at least two hours
with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any
sediment and sludge n o t volatiscd by the steam, is washed out during the steaming process.
BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely i n boiling
water containing a n effective alkaline degreasing agent or a dctcrgent, with the water filling and also
surrounding the tank for at least two hours.
After steaming or boiling a signed and dated label to this effect should be attached to the tank.

SPECIFICATION
Purchasers are advised that the specification details set out in this Manual apply to a range of vehicles and not to any
one. For the specification of a particular vehicle, purchasers should consult their Distributor or Dealer.

The Manufacturers reserve the right to vary their specifications with or without notice, and at such times and in such
manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer's
policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the
Manufacturer nor the Distributor or Dealer. by whom this Manual is supplied, shall in any circumstances bc held
liable for any inaccuracy or the consequences thereof.

COPYRIGHT
0Land Rover Limited 1984
All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any
form, electronic, mechanical, photocopying, recording or other means without prior writtcn permission of Land
Rover Limited, Service Department, Solihull, England.

...
Ill
 cardiagn.com
. Special Service Tools
The use of approvcd special scrvice tools is important. Thcy are essential if scrvicc opcrations arc
to be carricd out cfficicntly, and safely. The amount of timc which thcy save can be considcrable.
Every special tool is designcd with the closc co-operation of Land Rover Ltd., and no tool is put
into production which has not been tested and approvcd by us. New tools are only introduced
wherc an operation cannot be satisfactorily carried out using cxisting tools o r standard equipment.
The user is therefore assurcd that the tool is ncccssary and that it will perform accuratcly,
efficiently and safely.
Special tools bullctins will be issued periodically giving details of new tools as thcy are introduced.
All orders and enquiries from the United Kingdom should be sent dircct to V. L. Churchill.
Overseas orders should be placed with the local V. L. Churchill distributor, whcrc one exists.
Countries whcrc thcrc is no distributor may ordcr dircct from V. L. Churchill Limited, PO Box 3,
Daventry, Northants, England N N l l 4NF.

Thc tools rccommended in this Workshop Manual are listed in a multi-language, illustrated cataloguc obtainable from
Messrs. V. L. Churchill a t thc above addrcss under publication number 221?!2!84 or from Land Rover Ltd., under part
number LSM0052TC from the following address, Land Rover Publication Scrvicc, P.O. Box 534, Erdington, Birmingham,
B24 OQ5.
 LT77 FIVE SPEED GEARBOX 1371
-.x,,<::
6 ..;.,:+
'r :
:.:.a
; REMOVE LT77 FIVE SPEED GEARBOX AND 230R (a) Release the connection to the front pipe at
TRANSFER BOX - FOUR CYLINDER MODELS
.
.l
'::&,..
..._
.,-'
the flange.
(b) Release t h e connection to the rear section at
1. Install the vehicle on a ramp. the flange immediately behind the silencer.
2. Disconnect the battery. (c) Remove the 'U' bolt retaining the pipe to the
3. Remove the gear lever knob. bracket attached to the transfer box.
4. Remove the transfer and differential lock knob. 16. Mark the flanges for reassembly and disconnect the
5. Remove the gear lever cover. front propeller shaft from the transfer box.
6. Remove the 10 mm Nyloc nut and plain washer. 17. Similarly, disconnect the rear propeller shaft.
Mark the gear lever spline setting and dctach the 18. Disconnect the speedometer cable from thc rear of
gear lever and gaiter from the splined lower gear the transfer box.
lever. 19. Disconnect the handbrake inner cable by removing
7. Select high range to prevent the transfer gearbox the split pin and clevis pin.
selector lever fouling t h e tunnel when removing the 20. Slacken t h e retaining nuts and release the
gearbox. handbrake outer cable from t h e bracket.
8. Remove the bonnet. 21. Remove t h e two bolts and withdraw the clutch
9. Remove the nuts and bolts retaining the fan cowl to slave cylinder from the bell housing.
the engine and move the cowling forward, clear of 22. Manufacture a cradle to the dimensions given in
T the engine. the drawing and attach i t to a transmission hoist.
10. Release the transmission breather pipes, To achieve balance of the transmission unit when

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speedometer cable, and starter motor harness from mounted on the transmission hoist, it is essential
clips at rear of the engine. that point A is situated ovcr the centre of the lifting
11. Release clamp holding heater pipes on top of hoist ram. Drill fixing holes B to suit hoist table.
engine to prevent heater inlet pipe fouling Secure the transmission unit to the lifting bracket
bulkhead. at point C, by means of the lower bolts retaining
12. Raise the ramp. the transfer gearbox rear cover.
13. Remove the eight nuts and bolts securing the 23. Remove the bottom two bolts from the transfer
chassis cross member and using a suitable means of box rear cover and use them to attach the rear end
spreading t h e chassis, remove the cross member. of t h e cradle to the transfer box. Ensure that the
14. Place a suitable container under the transmission, tube in the centre of the cradle locates over the
remove the three drain plugs, allow the oil to drain extension housing drain plug.
and refit the plugs. Clean filter on the extension 24. Raise the hoist just enough to take the weight of
housing plug before refitting. the transmission.
15. Remove t h e intermediate exhaust pipe and silencer
section as follows:

\\ '' -IC
-IC U
0 0
6.1
19
9 0-25
5.0 6.0

508.0

UATERIAL ANC WELDING SPLCIFICATION

v 222.0
S t e e l Plate
Tuhr
Arc Welding
8s 1 4 4 0
HS 4 8 8 8
HS 5135
(Glade 1 or 1 4 )
(Part 2)
ST 637M

1
1371 LT77 FIVE SPEED GEARBOX

25. Remove the three nuts and bolts securing the transfer 41. Withdraw the transfer box. For LT230 transfer
box L.H. and R.H. mounting brackets to the chassis. gear box dismantling refer to page 19. Dismantling
26. Remove the nuts retaining the brackets to t h e information on LT77 gearbox, refer to page 3.
mounting rubbers and remove the brackets.
27. Lower the hoist sufficiently to allow the transfer Assembling transfer box to main gearbox
lever to clear the transmission tunnel aperture.
28. Disconnect t h e four-wheel drive indicator electrical 42. Hoist the transfer box into position and ensuring
lead (bullet connection). that the loose upper dowel is fitted, assemble to
29. Remove the cleat retaining the reverse light switch main gearbox extension housing and secure with
wires from the R.H. side of the gearbox. the four bolts and two nuts.
30. Disconnect t h e wire from the reverse light switch 43. Fit the transfer selector housing to the main
situated at the top rear of the selector housing and gearbox remote gear change housing with the four
rnove the harness away from the transmission. bolts. (The right hand rear bolt is longer).
31. Support the engine under the sump with a jack, 44. Fit the breather pipes.
placing timber between the jack pad and sump. 45. Fit the diffcrential lock cross shaft lever pivot
32. Remove the eleven hell housing nuts. bracket to the extension housing with thc two
33. Withdraw the transmission whilst ensuring all bolts.
connections to the engine and chassis are released. 46. Connect the cranked lever to the differential lock
lever with a new split pin. (On early production
Separating the transfer box from gearbox connect the short link with a new ‘Nyloc’ nut).

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Fitting main gearbox and transfer box to engine
47. Fit the cradle to the transmission hoist and the
transmission to the cradle as described in
instruction 23. Smear Hylomar on bell housing face
mating with engine.
48. Locatc the gear lcver temporarily and select any
gear in the main gearbox t o facilitatc entry of the
primary shaft.
49. Position and raise hoist and fit t h e transmission to
the engine whilst keeping wires and pipes clear to
prevent trapping.
50. Secure the transmission to the engine with the
eleven nuts, noting that the top R . H . nut holds a
clip for the speedometer cable.
51. Position the revcrse light wires to the R.1-I. side of
the main gearbox and secure with a cleat to the
breather pipes.
52. Connect the reverse light wire to the switch at the 1
top rcar of the selcctor housing.
53. Conncct the differential lock indicator wires (bullet
connection).
54. Raise thc transmission to line-up with the engine
and ensure that t h e transfer lever clears the tunnel
aperture.
55. Fit the transfer box L.H. and R.H. mounting
brackets but only partially tighten the securing nuts
and bolts.
56. Loosely fit the rubber mounting nuts and lower the
transmission onto the mountings. Fully tighten all
the securing nuts and bolts.
57. Remove the supporting jack from under the engine
,...--
aurrrp.
58. Remove the two bolts securing the cradle to the
transfer box and remove the cradle and hoist.
59. Refit thc two bolts using Loctite 290 on the threads
and note that t h e L.H. bolt holds a clip for the
speedometer cable.
60. Fit the slave cylinder using Hylosil on the gasket
and tighten the two bolts evenly to 22 to 28 Nm (16
to 21 Ib ft).
 LT77 FIVE SPEED GEARBOX (37I
61. Fit the handbrake cable using a new split pin to 4. Pull the clutch release lever from the clutch
secure the clevis pin. Grease the clevis and tighten release lever pivot.
the outer cable lock nuts. 5. Rcmove the bolts and washers securing the clutch
62. Connect the speedometer cable. release lever pivot.
63. Check that t h e three drain plugs are tight and
remove the main gearbox and transfer box filler
level plugs. Fill the main gcarbox with
approximately 1,76 litres (3 pints) of a
recommended oil or until it begins to run out of the
filler level hole. Fit and tighten the filler plug.
Similarly remove the transfer filler level plug and
inject approximately 2,6 litres (4.5 pints) of
recommended oil or until it runs out of the filler
hole. Apply Hylosil to the threads and fit the plug
and wipe away any surplus oil.
64. Line up the marks and fit the front and rear
propeller shafts to the transfer box.
65. Fit the exhaust system, and evenly tighten the
flange nuts and bolts. Fit the ‘U’ bolt and secure to
- the bracket. 6. Remove the bolts and washers securing the bell

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66. Expand the chassis side members, fit the cross housing and remove the bell housing.
member and secure with the eight nuts and bolts 7. Remove the three bolts and washers retaining the
(four each side). gear selector housing to the fifth gear extension
67. Fit the heater pipe clamp. case. Lift the housing from the case and discard
68. Clip the breather pipes, specdometer cable and the gasket.
starter motor harness to rear of engine.

P8
69. Fit thc fan cowl.
70. Fit t h e bonnet.
71. Fit main gear lever gaiter and lever, to previously
marked spline setting. Secure with the 10 mm
‘Nyloc’ nut (with plain washer) to the correct
torque.
72. Fit the cover to both gear levers.
73. Fit the gear lever knobs.
74. Connect the battery.

OVERHAUL LT77 FIVE SPEED GEARBOX

(4 cylinder petrol and diesel)
Service Tools:
18G705 - Bearing remover
-
18G705-1A Adaptor for mainshaft
18G705-5 -Adaptor for layshaft
18G1400 - Remover for synchromesh hub and gear
cluster
18G1400-1 -Adaptor mainshaft 5th gear
MS47 -Hand press
18G47BA -Adaptor, layshaft bearing remover
18647BAX -Conversion kit
186284 - Impulse extractor
18G284AAH - Adaptor for input shaft pilot bearing
track
ST541 M I I
1861422 -Mainshaft rear oil seal replacer
!8G!431 - Mainshaft 5th gear and oi! sea! cellar
replacer 8. Using a suitable pin punch, remove the roll pin
retaining the selector yoke.
Dismantle 9. Push the selector shaft forward to engage a gcar,
.. 1. Place gearbox on a bench with the transfer and manoeuvre the selector yoke from the shaft.
gearbox removed, ensuring the oil is first drained. Return the selector shaft to neutral.
2. Remove t h e clutch release bearing carrier clip. 10. Remove the circlip which retains the mainshaft oil
3. Remove t h e clutch release bearing and carrier. seal collar located at the rear of the gearbox.
3
 1
7
1 LT77 FIVE SPEED GEARBOX

W
21
ST542M ST 908M

11. Using tools 186705 and 186705-1A remove the 20. Release the circlip retaining the fifth gear
oil seal collar. synchromesh assembly to the mainshaft.
21. Using tools 18G1400-1 and 18G1400 withdraw the
selective washer, fifth gear synchromesh hub and

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cone, fifth gear (driven) and spacer from the
mainshaft.
22. Remove the split roller bearing assembly from the
main sh a ft.
23. Using tools 186705 and 18G705-1A remove the
layshaft spacer (if fitted) and layshaft fifth gcar.

12
/

ST543M

12. Remove the ten bolts and spring washers securing

the rear cover to the gearcase; withdraw t h e rear
cover and discard the gasket.
13. Fit two dummy bolts (8 x 35 mm) to the casing to
retain the centre plate to the main case.
14. Remove the oil seal collar ‘0’ring from the
mainshaft. ST
15. Withdraw the oil pump drive shaft.
16. Remove the two bolts and spring washers securing
24. Remove the selector shaft circlip.
the fifth gear selector fork and bracket.
25. Fit suitable guide studs (measuring 8 x 60 mm) to
17. Withdraw the fifth gcar selector spool.
the main gearbox case.
18. Withdraw the fifth gear selector fork and bracket.
26. Locate the gearbox to a suitable stand.
19. On early models, remove circlip retaining fifth
27. Remove the six bolts and spring washers from the
gear (driving) from the layshaft. On later models,
front cover. withdraw the cover and discard the
engage reverse gear by turning selector raii anti-
gasket.
clockwise and pulling rearwards. Move the fifth
28. Remove the input shaft and layshaft selective
speed synchro hub into mesh with the fifth gear.
washers from the gearcase.
De-stake the retaining nut securing the fifth gear
29. Remove the two bolts and washers securing the
iayshaft and remove nut. Select neutral by
pushing selector r;3il inwards and turning
clockwise; and return fifth speed synchro hub to
locating boss for the selector shaft front spool,
withdraw the locating boss. .
c-)
30. Withdraw the selector plug, spring and ball from
its out of mesh position.
the centre plate.
4
 LT77 FIVE SPEED GEARBOX 37
36. Rotate the fifth gear selector shaft clockwise
(viewed from above) to align the fifth gear
selector pin with the slot in the centre plate.
37. Remove the mainshaft and selector fork
assemblies from the centre plate.
38. Detach the selector fork assembly from the
mainshaft gear cluster.
39. Remove the slave bolts from thc centre plate and
lift the centre plate clear of the stand.

Front cover
40. Remove and discard the oil seal from the front
cover. Do not fit a new oil seal at this stage.

Layshaft
41. Using prcss 18G705 and tool 186705-5 remove
the layshaft bearings.

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31. Remove the dummy bolts and carefully lift the
gearcase, leaving the ccntre plate and gear
assemblies in position. Discard gasket.
32. Insert two slave bolts and nuts to retain the centre
plate to the stand; and remove the circlip, pivot
pin, reverse lever and slipper pad.
33. Slide the reverse shaft rearwards and lift off the
thrust washer, reverse gear and reverse gear
spacer.
34. Lift off the layshaft cluster.
' . 35. Remove the input shaft and fourth gear
synchromesh cone.

37- ST

. .

ST545M

5
 LT77 FIVE SPEED GEARBOX

Mainshaft
42. Remove the centre bearing circlip.
43. Using press MS47 and any suitable metal bar,
remove the centre bearing, first gear bush, first
gear and needle bearings and first gear
synchromesh cone.

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Input shaft
ST
55. Using tools MS47 and 18G47BA, reniovc the
input shaft bearing.
44. If a difficulty is experienced in removing the first
56. With the aid of tools 18G284AAH and 186284,
and second gear synchromesh hub, locate
cxtract the pilot bearing track.
underneath the sccond gcar with a suitablc tool;
and extract the complete synchromcsh hub and
second gear assemblies using a suitable press.
45. Using press MS47 and extension, with a support
underneath the third speed gear, press the
mainshaft through the pilot bcaring spacer, third
and fourth synchromesh hub, third gear
synchromesh cone, third gear and third gcar
needle roller bearing.

First and second gear synchromesh assemblies

46. Mark the hub and sleeve to aid reassembly and
remove the slipper rings from the front and rear of
the first and second gear synchromesh assemblies.
47. Withdraw the slippers and hub from thc sleeve.
4
ST 873M

Third and fourth gear synchromesh assemblies Reverse idler gear

48. Mark the hub and slecve to aid reassembly and 57. Remove the circlip from the reverse idler gear.
remove the slipper rings from the front and rear of 58. Having noted their positions, remove both ncedle
the assembly. roller bearings and remaining circlip from the
49. Withdraw the slippers and hub from the sleeve. gear.

Extension case Fifth gear synchromesh assembly

SO. Remove the three oil pump housing bolts, spring 59. Lever the backing plate off the fifth gear
washers and oil pump gears. synchromesh assembly.
51. Do not withdraw t h e oil pick-up pipe. 60. Remove the slipper rings from the front and rear
52. Remove the plug, washer and filter. of the assembly.
53. Invert casing and extract the oil seal. 61. Release the slippers and slide the hub from the
54. Press out the ferrobestos bush from the casing. sleeve.
6
 ~ 7 E S7PEED G E A RB O X
~ FIV 137 I
;c
3-
::- Centre plate Gear selector housing -Early models (Not illustrated)
.&&L\.S
v,,
62. Remove the layshaft and mainshaft bearing tracks (a) Rcmove the gear lever gaiter and three bolts
from the centre platc and reverse pivot post. holding the gear lever retaining plate and
anti-vibration pad.
Main gearbox casing (b) Remove gear lever from the gear lcvcr
63. Remove the mainshaft and layshaft bearing tracks housing.
from the main casing. (c) Removc the four bolts and spring washers
64. Remove the plastic oil trough from thz front of retaining the gcar levcr housing to the
t h e casing. selector housing. Lift off the housing and
discard the gasket.
Selector rail (d) Remove the bolts and washers retaining the
fifth gcar plunger assembly. Care must be
65. The selector rail is supplied complete with first taken not to lose the shims located on the
and second selector fork, pin and fifth speed plunger assembly casting.
selector pin. If it is required to replace the first (e) Withdraw the asscmbly from the selector
and second selector fork on its own, press out the housing and label components for
fifth speed gear selector pin and remove the first identification o n reassembly.
* . .. and sccond selector fork from the selector rail. 71. Rcmove thc bolts and washcrs retaining the
reverse gear plunger assembly. Care must be

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Gear selector housing - Latest models taken not to lose the shims located on the
assembly casting. Detach from the selcctor
66. Remove the roll pin and release the bias spring. housing and label components for identification.
67. Remove the two adjusting screws and locknuts. 72. Remove the locating bolt from the housing for
68. Remove the gear lcvcr cxtension, secured by a nylon bush. Pull the selector shaft rearwards and
nut (with p h i n wash er) . remove the trunnion housing.
69. Remove the bolt and special lock washer to 73. Release the circlip and detach the nylon insert
release the gear lever shaft from the trunnion from the trunnion housing.
housing. 74. Invert the gear selector housing and removc the
70. Remove the four bolts and spring washers fifth gear spool retainer bolts and spring washers.
retaining the gear lever housing to the selector Lift off the fifth gear spool retainer.
housing. Lift off the housing and discard the 75. Remove the large blanking plug at the rear of the
gasket. housing .
76. Remove the reverse switch blanking plug.
77. Place the gear selector housing into protected vice
jaws, using a suitable pin punch, drift out the
selector yoke roll pin. Push the selector shaft
forwards and remove the selector yoke. Remove
housing from vice.

./ .#

ST548M 77
78. Remove the selector yoke roller circlip and
withdraw the pin and rollers.
79. Withdraw the gear selector housing shaft out
through the large blanking plug orifice.
80. Remove and discard the gear selector shaft ‘0’
ring.
7
 LT77 FIVE SPEED GEARBOX

Fifth gear plunger assembly - Early models only 86. Inspect all gear teeth for chipped or broken teeth,
or showing signs of excessive wear. Inspect all
81. Remove the plug, long spring and detent ball spline teeth on the synchromesh assemblies. If
from the fifth gear plunger. there is evidence of chipping or excessive wear,
82. Remove the circlip which retains the fifth gear install new parts on reassembly. Check all slippers
plunger, pull out plunger and short spring. Keep and slipper rings for wear or breakage. Replace
all parts labelled and separated from the reverse with new parts if necessary.
' plungerassembly. 87. Inspect all circlip grooves for burred edges. If
rough or burred, remove condition carefully using
a fine file.
82 58. Ensure all oil outlets are clear of sludge or
contamination especially the mainshaft oil ways.
Clean with compressed air observing the
necessary safety requirements.
89. During the rebuild operation, it is recommended
that new roller and needle bearings are fitted.

ASSEMBLY

Layshaft

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ST549M
90. Using tools MS47 and a suitable tube, fit new
bearing cones to the layshaft.
Reverse gear plunger assembly
Synchromesh assemblies
83. Remove the plug, long spring and detent ball
91. With the outer sleeve held, a push-through load
from the reverse gear plunger assembly.
applied to the outer face of the synchromesh hub
84. Detach the circlip which retains the reverse gear
should register 8,2 to 10 kgf m (18 to 22 Ibf ft) t o
plunger, pull o u t the plunger followed by the
overcome the spring detent in either direction.
short spring. Labcl all parts and keep separate
92. Assemble the first and second synchromesh
from the fifth gear plunger assembly.
asscmbly by locating the shorter splincd face
towards the second gear.

92

ST551M

ST550M

Cleaning and inspection

85. Clean gearcase thoroughly using a suitablc
solvent. Inspect case for cracks, stripped threads
in the various bolt holes, and machined mating
surfaces for burrs, nicks or any condition that
would render the gearcase unfit for further
service. If threads are stripped, install Helicoil, or
equivalent inserts.
8
 LT77 FIVE SPEED GEARBOX I37 I
KEY

1.
2.
3.
4.
5.
6.
6A.
7.
8.
9.
10.
10A.
11.

T .

. .

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. .

9
 37 LT77 FIVE SPEED GEARBOX

93. Refit the slippers and locate the slipper rings to

each side of the assembly, ensuring that the
hooked ends of both slipper rings are located in
\ 53-0mm
the same slipper; but running in opposite \? 0.10
\
directions and finishing against the other t w o
slippers.

93 38.3mm
+0-005
-0-000 16-52 mm
+ 0-005
ST531M - o*ooo
98. Lubricatc the second gear needle bearing with a
light oil and fit the bearing, second gear and
synchromcsh cone to the mainshaft. It should be
noted that the second gear synchromesh cone has
larger slipper slots than the other synchromesh
cones.
ST552M 99. Fit thc first and second synchromesh hub
assembly with the selcctor fork annulus to the rear

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of the mainshaft.
94. Assemble the third and fourth synchromesh 100. Fit the first gear bush and slavc bcaring spacer
assembly and ensure the hooked ends are located and a new circlip to the mainshaft. When fitting
in the same slipper; and run in opposing directions the circlip, care must be taken to ensure it is not
and finally locate against the other two slippers. opened (stretched) beyond the minimum
95. Refit the fifth synchromesh hub assembly again necessary to pass over t h e shaft.
ensuring the hookcd ends of the rings are located 101. Press the slavc bearing spacer back against the
in the same slipper, but running in opposite circlip to allow the bush maximum cnd-float.
dircctions. Fit t h e backplate onto the rear of the Measure the clearance between the rear of thc
synchromcsh hub asscmbly. Ensure the tag on the first gear bush and front face of the slave bearing
backplate locates in the slot on the hub. spacer with a feeler gauge. The clearance should
96. Check the wear between all the synchromesh be within 0,005 to 0,055 mm. The first gear bush
cones and gears by pushing the conc against the is available with collars of diffcrcnt thickness.
gear and measuring the gap between the gear and Select a bush with a collar to givc t h e required
cone. The minimum clearance is 0,64 mm end-float. The bush must be free to rotate easily
(0.025 in). If this clearance is not met, fit new with the required cnd-float.
synchromesh cones. 102. Remove the circlip, slave bearing spacer and first
gear bush from the mainshaft.
103. First gear bushcs are available in the following
sizes:

Part N o . Thickness (mm)

FRCS243 40,16 - 40,21
FRC5244 40,21 - 40,26
FRC5245 40,26 - 40,31
FRC5246 40,31 - 40,36
FRC5247 40,36 - 40,41

104. Having selected a suitable first gear bush,

lubricate the needle bearing and fit to the first
gear.
105. Fit the selected bush to the first gear and placc
C--+
11131
----
gw1 -..--L-,.---l.
>yIICIIIuIIIG>II
C,.ll,...,nA
CUIIG;, 1uIIuwGu
h., + h a F:.-c+
uy LIIL 11131

gear assembly to the mainshaft.

ST553M
106. Using tools MS47, 18G47BA and 18G47BA-X
First gear bush end-float refit the centre bearing and circlip to the
mainshaft.
97. Manufacture a spacer to the dimensions provided 107. Invert the mainshaft, lubricatc the third gear
in the illustration, this will represent a slave needle roller bearing with light oil, fit to the front
bearing . end of the mainshaft.
10
 ~ 7 E S7PEED G E A R B O X
~ FIV 137
..
,,-:,A
..\./I. . .,... 108. Fit the third gear to the mainshaft; and locate the 118. Assemble and fit the fibre oil pump gears to the
?.,z,x: :i'
,_. ....
,4". I .."
.
I , third gear synchromesh cone to the third gear. oil pump cover, whilst ensuring the centre rotor
109. Fit the thirdlfourth synchromesh assembly (with squared drive faces the layshaft.
the longer box of the synchromesh hub to the
front of the gearbox) to the mainshaft.
110. Fit the spaccr and bearing to the front of the
mainshaft.

Input shaft
111. Using tool MS47 and any suitable tube, refit a 117
new pilot bearing track to the input shaft.
112. Fit the input shaft bearing using tools MS47,
18G47BA and 18G47BA-X.

Reverse Gear and Shaft

119

*
113. Fit a new circlip to the rear of the reverse idler
gear, ensuring that the circlip is not stretched
beyond the minimum necessary to pass over the
shaft.
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I

114. Lubricate with light oil and fit both needle roller
bearings. Fit the shorter necdle bearing to the
rear of the reverse idler gear.
115. Fit a new circlip to the front of the reverse idler
gear.

Extension case ST555M kz2

116. Using a suitable press, fit a new fcrrobcstos bush
to the case, ensuring t h c two drain holes are
119. Fit the three bolts and spring washers to secure
towards thc bottom of the case.
the oil pump covcr; and tighten to thc specified
torque.
120. Ascertain that the oil pick up pipe is free of
/-
._.-.'
contamination or blockage.
121. Fit a new oil filter, fibre gasket and tighten plug to
the specified torquc.

Centre plate
122. Fit the ccntre platc to a suitable stand and secure
with two slave bolts.
123. Place the new mainshaft and layshaft bearing
tracks to the centre plate.
124. Lightly lubricate the selector shaft with a light oil.
125. Take the selector shaft complete with the first and
second selector fork, front spool and third and
fourth selector fork; engage both selector forks in
their respective synchromesh slccvcs on thc
mainshaft, simultaneously engaging the sclcctor
shaft and mainshaft assemblies In the centre plate,
whilst rotating the fifth gear selector pin to align
/ iI

YI \1
h
'C.
with the slot in the centre plate.
126. Fit the layshaft to the centre plate.
.\
ST554M
127. Rotate the wler!or shaft and spoo! to emb!e !he
reverse crossover lever forks to correctly align to
the reverse pivot shaft. Reposition the selector
shaft and locate the lever between the fork on the
117. With the aid of tool 18G1422, fit a new oil seal to reverse gear pivot shaft. Insert pivot pin and fit a
the rear of the extension case. Ensure the seal lips new circlip, ensuring that it is not opened beyond
are towards the ferrobestos bush. Lubricate thc the minimum necessary to pass over the shaft.
seal lips with a suitable SAE 140 oil. 11
 El LT77 FIVE SPEED GEARBOX

126 130. Prior to assembly lubricate the detent ball and

spring with light oil, and fit to the top of centre
plate. Smear Hylomar PL32 or Loctite 290 to the
plug threads and screw the plug flush with the
case. Stake the plug to prevcnt rotation using a
suitable centre punch. Release the slave bolts.
131. Locate the fourth gear synchromesh cone to the
third/fourth synchromesh assembly.
132. Fit the input shaft to the mainshaft.
133. Fit the reverse gear spacer to t h c reverse gear
shaft.
134. Fit a new gasket to the centre plate.

Main gearbox casing

135. Insert a new plastic oil trough to the back of the
main gearbox casing, ensuring the open trough
faces the top of the case.
136. Carefully lower the gearcase into position over
t h e gear assemblies. DO NOT USE FORCE.

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This operation can be assisted by the use of two 8
x 100 mm guide studs. Ensure the centre plate
dowels and selector shaft arc engaged in their
respective locations.
137. Fit the layshaft and input shaft bearing outer
tracks.
128. Fit t h e slipper pad to the reverse lever. If a new 138. Using 8 x 35 mm slave bolts and plain washers to
reverse lever pivot shaft has been fittcd, it will be prevent damaging the rear face of the centre
necessary to ascertain that its radial location is plate, evenly draw the gcarcase into position on
consistent with the reverse pad slipper the plate.
engagementklearance. The radial location is 139. Fit the locating shaft front spool to the top of the
determined during initial assembly. gearcase using Hylomar PL32 to seal between the
spool and gearcase. Smear Loctite 290 or
Hylomar PL32 to the bolt threads, tighten bolts
and spring washers to the specified torque.
140. Manufacture a layshaft support plate and plain
washer to the dimensions provided in the
illustration.

U
ST557M '129

129. Fit the reverse gear spacer and reverse gear ST1118M
assembly, locating the slipper pad lip to t h e
reverse gear groove. Engage the reverse gear
shaft from the underside of the centre plate,
141. The layshaft support plate is fitted using two 8 x
25 mm bolts and washers to the front of the
gearbox, with the plain washer situated between
--
(-:;
ensuring the roll pin is aligned with the slot in thc the support plate and layshaft. The plate also
centre plate casing. retains the input shaft bearing outer track.
12
 ~ ~ FIV7E S7PEED G E A RB O X 137
L

~ ,?-:;a. . 1. 142. On early models: With the aid of a suitable press,

,.,E*.a.'i'
I *

fit the fifth gear, collar and new circlip to the

layshaft.
Later models: Fit the fifth gear to the layshaft
using a suitable press and loosely fit a NEW
special n u t . T o tighten the nut, hold the gearbox
firmly in a Vice and if necessary use a flange
holding wrench to restrain the gearbox. Tighten
the nut to 204 to 231 Nm (150 to 170 Ib ft). To
prevent damage to the adjacent bearings when
deforming the nut locking collar, support the fifth
gear with a block of timber. Using a round nose
punch carefully form the collar into the layshaft
grooves, as illustrated.

* . ...
, Part No. Thickness Part No. Thickness

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("1 (n1m)
FRC5284 5,lO FRC5294 5,40
FRC5286 5,16 FRC5296 5,46
FRC5288 5,22 FRC5298 5,52
FRC5290 5,28 FRC5300 538
FRC5292 5,34 FRC5302 5,64

147. Fit the correct selective spacer and new circlip.

Mainshaft and layshaft end-tloat

143. Locate assembly horizontally in a vice or suitablc
jig. 148. Measure and adjust the mainshaft and layshaft
144. Fit thc fifth speed washer, roller bearing, gear and end-float as necessary. Remove the layshaft
cone to the mainshaft. support platc from the front o f the gearbox.
145. Press fit fifth gear synchromesh hub assembly Part No. Thickness Part No. Thickness
using tool 1861431. Fit a dummy spacer with an ("> (")
oversize bore to ascertain thc correct spacer to
FRC4327 131 FRC4349 2,17
provide the specified clearance on the fifth gear.
FRC4329 137 FRC435 1 2,23
When fitting, care must be taken to ensure the
FRC433 1 1,63 FRC4353 2,29
hub assembly and selective spacer are NOT
FRC4333 1,69 FR C435 5 2,35
pushed too far on the mainshaft. Only fit with
FRC4335 1,75 FRC4357 2,41
sufficient clearance to allow the circlip to engage
FRC4337 1,81 FRC4359 2,47
FRC4339 137 FRC4361 2,53
FRC4341 1,93 FRC4363 2,59
FRC4343 1,99 FRC4365 2,65
FRC4345 2,05 FRC4367 2,71
FRC4347 2,11 FRC4369 2,77

149. When ascertaining thc mainshaft end-float care must

be taken when checking the dial gauge readings 10
ensure that the end-float only, as distinct from side
movement, is recorded. To overcome the difficulty in
differentiating betwecn end-float and side movement,
wrap approximately ten tums of masking tape around
the plain portion of the input shaft below the splines.
ST a m u Ascertain that the rise and faii of the input shaft is not
restricted by the tape.
146. Measure the clearance between the front spaccr 150. Place a mainshaft and layshaft spacer of nominal
and fifth gear (driven), which should be between thickness 1.02 mm on the mainshaft and layshaft
0,005 and 0,055 mm. Select the appropriate bearing tracks, fit the front cover and gasket tighten
spacer to provide the aforementioned clearance. bolts and spring washers to the specified torque.
151. Invert the gearbox on the stand. Rotate the mainshaft
to correctly seat the bearing.
13
1
4 LT"7 FIVE SPEED GEARBOX

152. Place a suitable ball bearing in the mainshaft 158. Fit a new oil seal to the front cover, ensuring the
centre and mount the dial gauge on the gearcase seal lips face towards the gearbox. Lubricate the
with the stylus resting on the ball bearing centre. scal lips with SAE 140 gear oil.
Zero the gauge. 159. Mask the splines with masking tape to protect the
153. Check the end-float by a 'push-pull' action to the oil seal. refit the front cover and remove the
mainshaft. The required mainshaft end-float spline masking tape.
measurement should be between 0,06 to 0,Ol mm 160. Refit the bolts and spring washers having used
with no pre-load. Hylomar PL32 or Loctitc 290 on the bolt threads.
154 Spacer thickness required equals; Nominal Tighten to thc specified torque.
thickness of spacer, plus end-float obtained. 161. Remove gearbox from the stand and place
Remove t h e dial gauge and ball bearing. suitably supported on the bench. Remove the
155 Rotate the layshaft to correctly seat the bearing. guide studs fitted to the centre plate.
Place a suitable ball bearing in the layshaft centre 162. Select reverse gear by turning the selector rail
and mount the dial gauge on the gearcase, with anti-clockwise and pulling rearwards. Move the
the stylus resting on the ball bearing centre. Zero fifth speed synchromesh hub into mesh with the
the gauge. fifth gear. Tighten the staked nut onto the fifth

I I ll Ill gear layshaft to the specified torque. Stake the nut

with a suitable ounch to secure. Select neutral bv
pushing selector rail inwards and turning
clockwise, thereby returning the fifth speed
synchromesh hub to its out of mesh position.

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Fifth gear selector fork assembly
163. Fit the fifth speed selector fork and bracket to the
fifth gear synchromesh hub assembly, cnsuring
that the largest groove lip is facing the rear of the
gearbox.
164. Fit the fifth gear spool to the selector shaft, rotate
and engage t h e selector fork into the groovc. It
should be noted that the longer shoulder of thc
spool is fitted towards the front of the gearbox.
165. Fit t h e fifth speed sclector fork brackct bolts and
spring washers. Tighten to specified torque.

156. With the aid of levers approximately 23 cm long;

, 164
to prevent component damage, check the end-
float by a gentle 'push-lift' action to the layshaft. 165
The required layshaft setting is:
0,025 mm end-float
0,025 mm preload.
Spacer thickness required equals; nominal
thickness of spacer, plus end-float obtained.
Remove the gauge and ball bearing.
157. Remove the front cover. Having ascertained the
mainshaft and layshaft end-float,-fit the mainshaft
and layshaft spacers of the appropriate thickness ST56,M
to the mainshaft and layshaft bearing tracks.
Selective spacers are available in a range of sizes 166. Fit a new circlip to the selector shaft ensuring that
to meet the aforementioned clearance limits. it is not expanded beyond the minimum necessary
Part No. Thickness Part No. Thickness to obtain entry.
167. Remove the six dummy bolts securing the centre
(") (") plate to the naiii casiiig.
TKC4633 1,69 TKC4649 2,17 168. Position thc gearbox assembly horizontally and fit
TKC4635 1,75 TKC4651 2,23 the oil pump shaft to the pump.
TKC4637 1.81 TKC46.53 2.29
TKC4639 1187 TKC4655 2135
TKC4641
TKC4643
1,93
1,99
TKC4657
TKC4659
2,41
2,47
Extension case
169. Fit a new gasket to the centre plate.
e.%-. 9.
k
+j

TKC464S 2,05 TKC4661 2,53 170. Rotate the oil pump to align with the oil pump
TKC4647 2,11 TKC4663 2,59 drive shaft.
14
 LT77 FIVE SPEED GEARBOX 37
c:;;:p$ 171. Carefully fit the extension case ensuring that the 180. Prior to reassembly, lubricate the following with a
. ...:. .
.:
.d oil pump shaft engages the layshaft. thin film of molybdcnum disulphide grease:
172. Fit the extcnsion case bolts and spring washers; (a) Clutch release lever fulcrum pivot socket.
tighten to specified torque. (b) The clutch release lever slipper pad pins and
173. Using a large screwdriver, ease the selector shaft the faces of cach slippcr pad.
forwards to selcct a gear. It may be found (c) Ball ends of the clutch opcrating push rod.
necessary to rotate the mainshaft to ease gear 181. Refit the slipper pads to the clutch release lever
selection. and locate the lever socket to the clutch release
174. Fit the selector yoke to the selector shaft and lever pivot.
secure with a new roll pin. Pull selector shaft 182. Lubricate the inner face of thc clutch release
rearwards to select a neutral position. bearing carrier with molybdenum disulphide
175. Cover the mainshaft splines with masking tape grease and fit to the front cover spigot, locating
and fit a new oil seal collar ‘0’ring. Remove the the clutch release lever slipper pads to the carrier
masking tape. recesses.
176. Using tool 1861431 fit the oil seal collar to the 183. Fit a new nylon clutch release carrier clip.
mainshaft, ensuring t h e collar is NOT pushed too 184. Refit the gearbox oil level plug, and tighten to the
far on the shaft, fit only with sufficient clearance specified torque.
to allow the circlip to engage in its groove. 185. Refit the gearbox oil drain plug and fit ncw fibre
177. Fit a new gasket to the top of the fifth gear washer. Tighten plug to specified torque.
- .
.. ., . ‘
~

extension case and fit the gear change housing by

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I

engaging male selector yoke with the female Reverse gear plunger assembly
yoke. Align the housing locating dowels and refit
the housing. Secure with the three bolts and 186. Lubricate the short spring and plunger with BP
washers; and tighten to the specified torque. Energrease L2 or similar prior to assembly.
187. Fit the short spring into the plunger base and slide
Bell housing the assembly into the rcvcrse gear plunger
178. Locate the bell housing to the dowels and fit the housing. Fit a new circlip to retain t h e plunger.
two long bolts (12 x 45 mm) with spring and plain Ensure the spring is not trapped, the detent
washers to the dowel positions. Thc remaining groove should be fully visible down the detent
four bolts (12 x 30 mm) are fitted with spring hole.
washers only. Tighten to the specified torque. 188. Lubricate the detent ball with light oil and fit into
its bore.
189. Refit the long spring and plug, coat the plug
threads with Loctite 290 or Hylomar PL32, and
I . 178 tighten to the specified torque.

The following instructions (190 to 21 I) relate to the early

model gearbox with a spring-loaded plunger for fifth
gear selection.

Fifth gear plunger assembly - Early models only

190. Lubricate the short spring and plunger with BP
Energrcase L2 or similar, prior to assembly.
191. Fit t h e short spring in t h c plunger base and slide
the assembly into the fifth gear plunger housing.
Fit a new circlip to retain the plunger. Ensure the
spring is not trapped, t h e dctent groove should be
fully visiblc down the detent hole.
192. Lubricate the dctent ball with light oil and fit into
its bore.
193. Refit the long spring and plug, coat the plug
threads with Loctite 290 or Hylomar PL32,
tighten to the specified torque.

Gear selector housing -Early models

ST562M 180b
194. Refit t h e gear selector rollers, pin and new circlip
L
1 .
^’
: I
ensuring circlip is not expanded beyond minimum
’ 179. Fit the clutch release lever pivot and securc with necessary to obtain entry.
t h e bolts and spring washers. Tighten to the 195. Lubricate the gear selector housing shaft with
specified torque. light oil and fit a new ‘0’ring.
15
 El LT77 FIVE SPEED GEARBOX
196. Insert shaft through the large blanking plug
orifice, ensuring the shaft indent is uppermost.
197. Place the gear selector housing into protected vice
jaws and fit the selector yoke to the shaft, using a
suitable pin punch and new roll pin. Remove the
housing assembly from the vice on completion.

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208. Remove the reverse plunger assembly, fit the
required thickness shim(s) refit the plunger
198. Fit the reverse switch and large blanking plugs. assembly, spring washers and bolts. ‘Tighten bolts
to the specified torque.
Coat plug threads with Loctite 290 and tighten to
209. Select third or fourth gear.
t h e specified torque.
199. Refit the fifth gear spool retainer, coat the bolt 210. Locate the fifth gear plunger on the left hand sidc
viewed from the rear, giving Sufficient load on the
threads with Loctite 290, and tighten the bolts and
trunnion to eliminate sideplay. Whilst
washers to the specified torque.
maintaining a light finger pressure, measure the
200. Fit a new nylon insert into the trunnion housing
clearance between the plunger assembly casting
and secure with a new circlip.
and gear selector casting. Add 0,6 nim to the
201. Invert the gear sclector housing and fit the
measured figure and select suitable thickness
trunnion housing to the selector shaft, ensuring
shims to equal the total.
the locating bolt aligns with the shaft indent. Coat
the bolt threads with Loctite 290. Tighten bolt to
the specified torque.
202. Fit a new gear lever housing gasket and fit the
gear lever housing, spring washers and bolts.
Tighten bolts to the specified torque.
203. Coat the upper and lower balls of the gear lever
shaft with BP Energrease L2 or similar. Push
lever into the trunnion nylon bush.
204. Place new vibration pad over the gear lever and fit
the gear lever retaining plate. Refit the three
shouldered bolts and tighten to the specified
torque.
205. Refit the gear lever gaiter and attach the gear
lever extension. Then carry out the following
procedure to ensure a clearance of 0,3 to 0,9 mm
between the gear lever yoke and stops.
206. Select first or second gear. It may be necessary to
rotate the mainshaft whilst manipulating the gcar
lever.
297. Locate tne reverse gear piunger on the right hand
211. Remove the fifth gear plunger assembly and fit
side viewed from the rear, giving sufficient load
the required shim(s), refit the plunger assembly,
on the trunnion to eliminate side play. Whilst
spring washers and bolts. Tighten bolts to the
maintaining a light finger pressure, measure the
specified torque.
clearance between the plunger assembly casting
and gear selector casting. Add 0,6 mm to the
measured figure and select suitable thickness
shims to equal the total.
16
 LT77 FIVE SPEED GEARBOX 1
3
.,..
P The latest model gearbox employs a spring-loaded 227. Fit the fifth gear stop o n the left hand side viewed
1.
..
,.- ;.
~

biased gear change lever assembly and the following from the rear, giving sufficient load on the
instructions (212 to 236) include the fitting and trunnion to eliminate side play. Whilst
adjustment of this arrangement. maintaining a light finger pressure, measure the
clearance between t h e plunger assembly casting
Gear selector housing and gear selector casting. Add 0,6 m m to the
212. Refit the gear selector rollers, pin and new circlip measured figurc and select suitable thickness
ensuring circlip is not expanded beyond minimum shims to equal the total.
necessary to obtain entry. 228. Remove the fifth gear stop, fit the required
213. Lubricate the gear selector housing shaft with thickness shim(s). Refit the gear stop assembly,
light oil and fit a new ‘0’ring. spring washers and bolts. Tighten bolts to the
214. Insert shaft through the large blanking plug specified torque.
orifice, ensuring the shaft indent is uppermost. 229. To adjust the bias springs with the unit completely
215. Place the gear selector housing into protected vice assembled, engage either third or fourth gear.
jaws and fit the selector yoke to the shaft, using a
suitable pin punch and new roll pin. Remove the
housing assembly from the vice on completion.
216. Fit the reverse switch and large blanking plugs.
Coal plug threads with Loctitc 290 and tighten to
- ~ the specified torque.

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217. Refit the fifth gear spool retainer and tighten the
bolts and washer 7 Nm (5 Ibf ft) and fit a new
nylon insert into the trunnion housing and secure
with a new circlip.
218. Invert the gear selector housing and fit the
trunnion housing to the sclector shart, ensuring
the locating bolt aligns with the shaft indent. Coat
the bolt threads with Loctite 290. Tighten bolt to
the specified torque.
219. Fit a new gear lever gasket and locate the gear
lever housing, spring washers and bolts. Tighten
bolts to the specified torque.
220. Fit the two bias spring adjustment screws and lock
nuts.
221. Place the bias spring in position with the spring
legs either side of the gear lever housing and
retain with a roll-pin.
222. Coat the upper and lower spheres of the gear 230. Adjust the two adjusting screws until both legs of
lever shaft with Duckhams Q.5848 or Shell the spring are approximately 0,5 mm clear of the
Alvania R I and locate the lever in t h e gearbox cross-pin in the gear lever. This should allow a
and retain with the bolt and special lock washer. certain amount of radial movcmcnt of the gear
223. Using a screw driver lift the bias spring legs over lever without the cross-pin contacting either of thc
the gear lever crosspins. Do not overstress the spring legs.
spring legs. Refit the main gear lever with the 231. Apply a slight load to t h e gear lever knob in a left
gaiter. Align the marks made when dismantling. hand dircction to position the gear lever at one
Tightcn the 10 mm ‘Nyloc’ nut. extreme of the radial play. Adjust the right hand
224. Select first or second gear. It may bc necessary to adjusting screw downwards until the right hand
rotate the mainshaft whilst manipulating the gear spring Icg just makes contact with the cross-pin o n
lever. the right hand side.
225. Locate the reverse gear plunger assembly on the 232. Repeat instruction 229 in the opposite direction.
right hand side viewed from rear, giving sufficient 233. At this stage, radial play will still be present, but
load on the trunnion to eliminate side play. Whilst at the other extreme the cross-pin should just
maintaining a light finger pressure, measure the make contact with the spring leg on the other side.
c!e2!2r?ce between the p!unger assemb!y casting 234. rI r _..._..
u w c I 50th adjustiiig screws equal ~ m ~ i i iiiiitil
ii~
and gear selector casting. Add 0,6 n i m ’ t o the the radial play is just eliminated. Tighten
measured figure and select suitable thickness lockn u ts.
shims to equal the total. 235. Return gear lever to neutral position and rock
226. Remove the reverse plunger assembly, fit the across the gate several times. The gear lever
required thickness shim(s) and refit the plunger should return to the third and fourth gate. If not,
assembly, spring washers and bolts. Tighten to the repeat the aforcmentioned procedure.
specified torque. 236. Fit the rubber gaiter and secure with a strap.
17
E[ LT230R TRANSFER GEARBOX

LT 230 R TRANSFER BOX RENEW FRONT OUTPUT SHAFT OIL SEAL

W

The following operations can be carried out with the Special tool:
gearbox in the vehicle. For ease of working, the vehicle 18G1422
should be raised on a ramp or placed over a pit. Also, 1. Disconnect the front propeller shaft from the
the battery should be disconnected for safety. flange and move to one side.
2. Remove the output shaft nut and washer and
RENEW SPEEDOMETER DRIVE PINION withdraw the flange.
1. Raise the vehicle on a ramp. 3. Remove the oil seal shield.
2. Remove the speedomcter drive clamp and nut and 4. Prise out the oil seal(s).
withdraw the cable.
NOTE: The double-lipped oil seal supersedes the
3. Prise out t h e drive pinion assembly.
two oil seals used on early production.
4. Push in a new assembly and fit the speedometer
cable and secure with the clamp and nut. 5. Using special oil seal replacer tool 1863422 fit the
double-lipped oil seal, open side inwards, with the
RENEW REAR OUTPUT SHAFT OIL SEAL seal in contact with t h e bearing circlip, taking care
not to touch the scal lip.
Special tool: 6. Lubricate the running surface of t h e flange and fit
18G1422 it together with the oil seal shield.

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7. Secure the flange with t h e nut and washer and
1. Disconnect the battery for safety.
tighten to 146 to 179 Nm (108 to 132 Ib ft).
2. Disconnect the rear propshaft from the output S. Refit the propeller shaft.
flange.
3. Remove thc brake drum retaining screws and REMOVE INTERMEDIATE SHAFT AND GEARS
withdraw the drum.
4. Remove the two back plate bolts that also retain Service tool:
thc oil catcher and remove the catcher. R0605862
1. Drain the transfer gearbox oil.
NOTE: An hexagonal type socket should be used for
2. Disconnect the rear propshaft from the output
these bolts.
flange.
5 . Remove the output shaft nut and washer and 3. Remove the two screws and withdraw t h e brake
withdraw the flange. drum.
6. Using thc slot provided, lever off the dust cover. 4. Remove the four bolts securing the brake back
7. Prise out the output shaft oil seal(s). plate and withdraw the back plate and oil catcher.
8. Using special tool 1861422 fit the doublc-lipped oil
seal, open side inwards, with the seal in contact NOTE: An hexagonal type socket should be used for
these bolts.
with the bearing circlip, taking care not to touch
the seal lips. g-2
5. Remove the intcrmediatc shaft keeper plate, -.-

NOTE: The double-lipped oil seal supersedes the retained by a single bolt.
two oil seals used on early production. 6. Remove the ten bolts and remove the bottom cover
plate.
9. Fit the dust cover. 7. Using service tool R0605862 withdraw the
10. Lubricate the surface of the flange which runs in intermediate shaft whilst holding the gear cluster.
the seal and carefully fit the flange. Collect the bearings and thrust washers from both
ends of the cluster.
NOTE: To renew the flange bolts first remove the 8. Remove the two ‘0’ rings, one from the shaft, the
circlip before fitting the flange. other from the casing.

11. Secure the flange with the nut and washer and Fit intermediate shaft gears
tighten to 146 to 179 N m (108 to 132 Ib ft). 9. Fit the ‘0’ ring to thc intermediate shaft.
12. Fit oii catchei to the “u& using si~icoiie
i0. Fit t h e -0‘ring into the front of the transfer case.
rubber sealant and secure with the two back plate 11. Lubricate thrust washers, bearings, shaft and
bolts (with plain washers). spacer.
13. Fit the brake drum and retain with the two screws. 12. Fit needle bearings with spacer interposed.
14. Reconnect t h e propeller shaft. 13. Fit front thrust washer to slot in transfer case (plain
6.’.
side to case). \ N’

14. Locate gear assembly partially into the transfer

case so that it rests o n the front thrust washer.
18
 LT230R TRANSFER GEARBOX 137 I
._..._
.<, :-,.
_(-.-_ 15. Locate rear thrust washer (plain side uppermost)
X=>,,..j
_..
.* 1_... ' .I into slot in transfer case.
16. Gently push gear assembly into mesh.
17. Using a screwdriver through the intermediate shaft
hole guide thc locating tab on the rear thrust
washer into the slot provided in the transfer case.
18. Align gear and thrust assembly and slide the
intermediate shaft into the transfer box from the
rear.
19. Align the shaft so that the lock plate in the end is
on top.
20. Apply Loctite 290 to the lock plate bolt threads.
Locate lock plate into position and fit securing bolt
(with spring washer).
21. Lever the gear.assembly to one side and measure
the end-float with feeler gauges. This should be
between 0,08 and 0,35 mm (0.003 and 0.014 in).
22. Grease and fit the bottom cover joint washer.
23. Apply Loctite 290 to the ten bolts and evenly
T

.. .... .... ~ tighten to 22 to 28 N m (16 to 21 Ibf ft).

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''

':., ,. 24, Fit the oil catcher to the brake plate, using silicone
rubber sealant and secure the backplate with the
four bolts. The t w o bolts securing the oil catcher
are fitted with plain washers.
25. Fit the brake drum and retain with the two screws.
26. Connect the rear prop shaft.
27. Refill t h e transfer box with the correct oil.

.,....
":.
,. .....
:' L.:
I ..

19
 LT230R TRANSFER GEARBOX

OVERHAUL LT230R TRANSFER GEARBOX 6 . Disconnect the bottom of the high/low connecting
rod from the high/low operating arm by removing
Service tools: the split pin and clevis pin.
RO 605862 -Intermediate shaft removal 7. Remove the plastic bushes from the operating
18G1273 -Sed1 remover arm.
18G1205 -Flange wrench 8. Remove the gearchange housing complete with
18G257 -Circlip pliers linkage.
18G1422 -Oil seal replacer
18G1423 - Stakenut remover
MS47 -Hand press
18G47BB/1- Collars
18G47BB/3 - Button
18G47BB/2 -Collars
1801424 -Differential centre bearing drift 8
18G47-7 -Collars and buttons
LST 47-1 -Collars

REMOVE ASSEMBLIES FOR OVERHAUL

(Instructions 1 to 33)

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1. Having removed the complete gearbox and
transfer box assembly. The transfer box is
separated from the gearbox on the work bench.

NOTE: To facilitate removal of various items on

the work bench, obtain suitable wooden blocks to
enable the transfer box to be turned and propped
up as required.

Hand brake linkage removal

2. Remove the split pin and clevis pin to release the
handbrake linkage from the brake operating
lever.
3 . Remove the two bolts (with spring washers)
securing t h e rear end of the handbrake mounting
bracket to the casing, the lower bolt is shorter.
4. Remove the two bolts (with spring washers and
distance pieces) securing the front sidc of the
handbrake mounting bracket and remove from
the transfer box.

Transfer box mounting removal

5 . Remove the bolts retaining the right hand rubber
mounting plate.
20
 ~ ~ 2 TR 0 SFE
3 AN ~ R G E A RB O X 137I

GENERAL ARRANGEMENT OF LT230R TRANSFER GEARBOX

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4

21
 LT230R TRANSFER GEARBOX

GENERAL ARRANGEMENT OF TRANSFER GEARCHANGE HOUSING

1. Main selcctor lever.

2. Transfer gear selector assembly.
3. Differential lock selector assembly.

1
. -

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5

f;

ST886M
P
‘
-*
J

22
 LT230R TRANSFER GEARBOX 1371
Transmission brake removal
9. Remove the two countersunk brake drum
retaining screws and pull off the drum.
10. Removc t h e four bolts securing the brake
backplate, two of these also retain the oil catcher.

NOTE: An hexagonal type socket should be used

for these bolts.

Bottom cover removal

11. Hemove the ten bolts retaining the bottom cover.

Intermediate shaft removal

12. Remove the shaft lock plate retained by a single
bolt at the rear face of the transfer box.

Power take off cover removal

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17. Remove the four bolts retaining the circular
P.T.O. cover and the speedometer cable clip
plate.
18. Removc the gasket.

NOTE: The other two bolts were removed with the

gearbox assembly cradle.

13. Withdraw the intermediate shaft, using a screw

driver in the slotted end. Where the shaft cannot
be easily withdrawn use extractor R0605862.

14. Lift out the intermediate gear cluster, roller

bearings and spacer.
15. Remove the thrust washers.
16. Remove the '0' ring from the intermediate shaft ST 1
and the transfer box case.
(371 ~ ~ 2 TR 0 SFER
3 AN ~ G E A RB O X

Input gear removal 30. Remove the centre differential unit with the
selector shaft/fork assembly.
19. Remove the two countersunk screws and release
the mainshaft bearing housing.
20. Remove the gasket.
21. Remove the input gear assembly.
22. Prise out and discard the oil seal at the front of the
transfer case using service tool 1861271.
23. Drift out the input gear front bearing track.

Highhow selector housing removal

24. Remove the six bolts to release the selector
housing.
25. Remove the gasket.

ST1165M

Rear output shaft housing assembly removal r4 zl- L.

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. a: *
..bi’
31. Remove t h e six screws to relcase the housing. The
upper screw is longer.
32. Remove the gasket.

NOTE: Removal of the above housing will reveal

the centre differential rear bearing track in the
transfer box casing. Before drifting out, either
unscrew the two studs and radial dowel projecting
from the transfer box front face or use suitable
wooden blocks to support the box to avoid damage
to these items.

33. Drift out the differential rear bearing track.

NOTE: If it is required to completely strip down

the transfer box to the basic casting, remove the
level, filler and drain plugs.
Front output shaft housing removal f-,
IMPORTANT: Clean all parts ensuring any traces --.
26. Slacken the square headed set screw securing the of Loctite are removed from faces and threads.
yoke to the high/low selector shaft inside the Ensure that the magnetic drain plug is thoroughly
highhow selector housing aperture. cleaned. Renew oil seals and examine all other
27. If necessary use a screw driver to move the parts for wear or damage, renew as necessary.
selector shaft rearwards and allow thc yoke to be
lifted out.
28. Remove the eight bolts to release the front output
shaft housing assembly. The upper middle bolt is
longer.

NOTE: The ‘radial’ dowel in the transfer box face

should not be disturbed.

Centre differential removal

29. Remove the high/low selector shaft detent plug,
spring and ball.

NOTE: The ball may be more easily retrieved from

inside the transfer case after the selector shaft is
taken out.
24
 LT230R TRANSFER GEARBOX 1371
Reassembling 46. Remove the speedometer driven gear and spindle

n
from the spindle housing.
34. Ensure that all faces of t h e transfer box are clean. 47. Remove the ‘0’ ring and oil seal.
35. Check that level/filler and drain plugs are in
position.
36. Fit the two studs which are used for part retention
of the extension housing.
37. Screw in the ‘radial’ dowel. It is important that its
projecting blade is set radially in line with the
tapped fixing hole centres in the transfer box
casing.

Rear output shaft housing - Overhaul (Instructions 47

to 73)

Dismantling
38. Using flange wrench 1861205 remove the flange
nut. steel and felt washers.

NOTE: Ensure flange bolts are fully engaged in the

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wrench.

h 38
48. Slide off the spacer and speedometer drive gear
from the output shaft.
49. Clean all parts, renew oil seals and Nyloc flange
nut and examine all other parts for wear or
damage, renew as necessary.

Reassembling
50. Press the output bearing into t h e housing. D o not
use excessive force. If necessary warm the housing
and case.
51. Fit the bearing retaining circlip using circlip pliers
186257.
52. Fit a new dual lip oil seal (open side inward), with
the seal in contact with the bearing circlip it is
essential to use replacer tool 1861422.

NOTE: On early production two separate seals

were used, these should be replaced with the new
39. Remove the output shaft flange with circlip dual lip seal.
attached. If necessary, use a two-legged puller.

NOTE: The circlip need only be released if the

flange bolts are to be renewed.

40. Remove the speedometer spindle housing. This

00
can be prised out with a screw driver.
41. Remove assembly from vice and support the
housing to allow removal of the shaft, drifting it
out by striking the flange end of the shaft.
42. CarefL!!!y prise nff the oi! catch ring llsing 2 screw
driver in the slot provided.
43. Prise out and discard the seal(s) using tool
18G 1271. 52
44. Using circlip pliers 18G257 remove the circlip
retaining the bearing.
45. Drift out the bearing from the back of the
ST903 M
housing.
25
 (37I LT230R TRANSFER GEARBOX

53. Carefully charge the lips of the seal with grease. Centre differential Unit -Overhaul
54. Fit oil catch ring on to housing.
55. Fit oil seal into speedometer spindle housing (Instructions 66 to 119)
(open side inwards) with a suitable tubc.
56. Fit ‘0’ ring to speedometer spindle housing. Dismantling
57. Lubricate seal and ‘0’ring with oil.
58. Locate speedometcr driven gear and spindle in 66. Detach the high/low selector shaft and fork.
spindle housing and push into position.
59. Slide speedometcr drive gear and spacer onto
output shaft.
60. Fit output shaft to the bearing in the rear output
shaft housing.
61. Examine the flange seal track to check for any
damage that may harm the seal. Retain for fitting
later.
62. Locate speedometer spindle housing assembly in
the output shaft housing and push in flush with
housing face.

-NOTE: Before fitting the rear output shaft housing

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to the transfer box casing the centre differential
rear bearing track must be fitted.
ST1189M I1 I I II I

63. Drift the centre differential rear bcaring track into

the transfer box casing 1,5 mm (:,; in) below the
outer face of the casing. Check the depth before 67. Using soft jaws secure the differential unit in a vice
proceeding. with t h e ‘stake’ nut uppermost.
68. Remove the peened-ovcr metal to facilitatc
Fitting rear output shaft housing to transfer box removal of t h e nut.
69. Remove the ‘stake’ nut using tool 18G1423.
64. Grease and fit housing gasket and locate the
70. Remove the differential unit from the vice.
housing in position on the transfer box.
71. Secure hand press MS47 in vice with collars
18G47BB/1 and using button 18G47BB/3 remove
NOTE: If the differential rear main bearing track
rear taper (twenty-four) roller bearing and collars
has been correctly fitted there will be a gap
LST 47-1 for latest (twenty-three) roller bearing.
between the housing face and the gasket at this
72. Substituting collars 18G47BW2 remove front
stage.
taper roller bearing.
73. Remove the hand press from the vice.
65. Apply Loctite 290 to the threads of the six housing
securing screws, noting that the upper screw is
longer. Fit the screws (with spring washcrs)
evenly tightening them to the specified torquc.
This will press in thc rear main bearing track to
the correct position and seat thc housi3g.

STl166M ii i

74. Remove the high range (smallest) differential

f=:.
gear and its bush. ’\d
75. Mark the relationship of the highhow selector
sleeve to the hub and remove the sleeve.
26
 LT230R TRANSFER GEARBOX 137
--.,,.,
^... ‘h 76. Using a suitable press behind the low range Obtaining differential backlash by checking bevel gear
...c:.
*.I..

? . II
~

... (largest) gear carefully remove both high/low hub end-float

and low range gear together. Alternatively, the
rear carrier bearing, high output gear and bush, 84. Using soft jaws secure the rear differential case in
high/low hub and sleeve and low output gear can the vice by gripping the inner hub splines.
be pressed off in one operation by supporting the 85. Ensure that all differential components are dry to
differential side of the low gear. assist in checking end-float.
77. Using soft jaws secure the differential unit in the 86. Using a micrometer measure one of the bevel gear
vice by gripping the inner hub splines. thrust washers and note thickness.
78. Remove the eight retaining bolts and lift off the 87. Fit the thrust washer and bevel gear to the rear
front differential case. (lower) differential case.
79. Lift off the front (upper) bevel gear and thrust 88. Assemble the side gears and dished washers on
washer. their respective shafts and fit to the rear case.
80. Remove both pairs of side gears with their 89. Measure the remaining bevel gear thrust washer,
respective shafts and dished washers together. noting its thickness.
81. Lift out the remaining rear (lower) bevel gear and 90. Fit the thrust washer and bevel gear to the front
thrust washer. case.
82. Remove the rear differential case from the vice. 91. Fit and align the front differential case tightening
83. Clean all parts, examine for wear or damage, the eight securing bolts to the specified torque.
1

renew as necessary. 92. Ensure that the front bevel gear is fully in mesh by

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1

tapping i t down, using a punch through the front

differential case.

ST1169M
W

93. Measure the front bevel gear end-float with feeler

gauges through the slots provided in the front
differential case. This must be between 0,25 and
99 - 0,75 mm (0.001 and 0.003 in) maximum.
fG=?a 94. Invert differential unit in vice and repeat the
above procedure (items 92 and 93) for the rear
bevel gear in the rear differential case.
95. Return the differential unit to its former position
in the vice i.e. with t h e front differentid case
uppermost.

. I>

ST1171M
27
 13'71 LT230R TRANSFER GEARBOX

0 .,:;::-
-U'

ST1170M
96. Remove the eight securing bolts and lift off the
front differential case. 112. Fit the 'stake' n u t using tool 1861423 and tighten
to the specified torque.
97.. Remove the bevel gears and thrust washers, and -e;?-...

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side gear asscmblies. 113. Peen the nut flange into the slot provided.
114. Remove the differential unit from the vice. '42:
98. Select correct thrust washers required for final
reassem bly. 115. Lubricate gears, bearings, sleeve and bush with
oil.
Reassembling 116. Clean and check the high/low selector fork
99. Fit the selected thrust washer and bevel gear to assembly for wear and rencw if necessary.
the rear (lower) differential case. 117. To renew the selector fork remove the square set
100. Assemble the side gears and dished washers o n screw retaining i t to the selector shaft and ensure
their respective shafts and fit to the rear case. any traces of Loctite are removed from the
101. Fit the other selected thrust washer and bevel gear threads.
to the rear case. 118. Refit the selector fork with the fork boss towards
102. Lubricate all parts with oil. the three detent grooves. Align thc hole in the
103. Fit and align the front differential casc, locate the fork boss with the indent in the shaft nearest to
eight securing bolts and tighten to the specified the detent grooves.
torque. 119. Apply Loctite 290 to the set screw threads and fit
104. Finally check that the differential gears revolve the set screw to the correct torque.
freely. 120. Prop up the transfer box so that its front side is
105. Place the front (outer) differential bearing on the uppermost.
121. Fit the selector fork to the high/low selector
front differential case and press into position
using larger end of tool 18G1424. sleeve in the differential assembly. g..
... .
-, ,..,

106. Invert the differential unit in the vice. 122. Locate the differential assembly and highllow .''-

107. Fit t h e low range gear (largest) to the rcar selector fork assembly into the transfer casc. It
differential case (with its 'dog' teeth uppermost). may be necessary to rotate the output shaft to
108. Press the high/low hub onto the splined area of ease fitment.
the case. Check end-float of low range gear. See 123. Fit the selector shaft detent ball and spring, apply
Data at end of section. Loctite 290 to t h e detent plug threads, screw in
109. Slide the highhow selector sleeve onto thc hub the detent plug until the spring is just coil bound,
outer splines, observing the alignment marks. then back off two complete turns.
110. Fit the bush into the high range (smallest) gear
and slide the bushed gear onto the rear
differential case. Check end-float of high range
gear and running clearance of gear on bush. Scc
data at end of section.

NOTE: If the clearances vary considerably from

those specified in the data the assembly must be
rebuilt.

111. Place the rear differential bearing on the rear

diffcrcntial case and press into position using t h e
smaller end of tool 1861424. ST1190M
28
 LT230R TRANSFER GEARBOX

,?:I,
. .,:".\. ,%a Front output shaft housing -Overhaul 128. Remove the detent plug from the top of the
... .,...,..
.I,.. I

housing and lift out the spring and ball using a

(Instructions 125 to 175) magnet.
129. Compress the selector fork spring inside the
Dismantling housing and slide out the spring locating 'C' caps.
130. Slide the sclcctor shaft out of the rear of the
124. Secure the housing in the vice, using soft jaws. housing.
125. Remove the seven screws securing the differential 131. Remove the selector fork and spring through the
lock selector side covcr and release thc side cover side cover aperture.
and gasket. 132. Lift o u t dog sleeve from the back of the output
126. Remove the three screws securing the differential shaft housing.
lock finger housing and lift O u t the complete 133. Using the flange wrench 18G1205 remove [he
assembly. flange nut, steel and felt washers. A two-legged
puller may be necessary.

NOTE: Ensure that flange bolts are fully engaged

126 in the wrench.
e
9
134. Remove the output shaft flange with oil seal
shield.

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NOTE: These parts need not be separated unless
the flange bolts are to be renewed.

ST1 I 7 3 M

127. Slacken the lock nut retaining the differential lock

switch and unscrew the switch. 135. Drift the front output shaft rearwards o u t of the
housing.
136. Slide off the collar from the output shaft.
127, d--
1- 128 /
137. Prise out and discard t h c oil seal(s), using service

29
137I LT230R TRANSFER GEARBOX

138. Using circlip pliers 186257 remove the circlip. 155. Engage high or low gear.
139. Remove the housing from the vice and drift out the 156. Check the rolling resistance of the differential,
bearing from inside. using a spring balance and a piece of string wound
140. Press out the differential front bearing cup and around the exposed splines on the high/low hub.
remove the shim behind it. Little or no resistance will register.
141. Clean all parts ensuring that any traces of Loctitc 157. Tighten the bolts a little at a time, occasionally
are removed from faces and threads. checking the rolling resistance. With the correct
142. Renew oil seals and examine all parts for wear or shim selected and the bolts tightened to thc
damage, renew as necessary. specified torque a pull of 1,s to 4,5 Kg (4 to 10 Ib)
is required on the spring balance. This applies to
Reassembling new or used bearings.
158. If the reading is outside the abovc limits remove
143. Press the front bearing into the housing. Do not
the front output shaft housing assembly from the
use excessive force, if necessary, warm the
transfer case.
housing assembly and case.
159. Using a suitable extractor, withdraw the front
144. Fit the bearing retaining circlip, using circlip pliers
differential bearing cup from the housing and
186257.
exchange the shim for one of suitable thickness.
145. Fit a new dual lip oil seal (open side inward) until
160. Rcfit the bearing cup.
the seal is in contact with the bearing circlip. It is
161. Having obtained the corrcct rolling resistance
essential to use replacer tool 1861422.

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prop-up the transfer box on the bench with thc
front sidc uppermost.
NOTE: On early production two separate seals
162. Grease and fit the front output shatt housing
were used, these should be replaced with the new
gasket and locate the housing on the transfer box.
dual lip seal.
163. Apply Loctite 290 to the threads of the housing
securing bolts and fit the eight securing bolts (with
spring washers). Note that the upper middle bolt
is longer.
164. Turn the transfer box i n t o its normal operating
position.
165. Fit both input and output flanges as follows.
166. Using flange wrench 18G1205 and a torque
wrench pull up output shaft to corrcct position.
Check that the oil seal shield does not foul the
housing .

NOTE: Ensure that flange bolts are fully engaged

in the wrench.
- --
STSOSM

146. Carefully charge the lips of the seal with grease.

147. Slide the collar onto the front of the output shaft
with its chamfered edge to the front.
148. Fit the output shaft through the back of the
housing.
149. Examine the flange seal track to check for any
damage that may harm the seal.

Obtaining bearing pre-load

150. Measure the original differential front bearing
track shim, noting its thickness.
151. Refit the original shim.
152. Drift the differential front bearing track into the
housing.
153. Grease and fit a new gasket and locate the front
output shaft housing on the transfer box.
154. Loosely retain the h. ,sing with the eight securing
bolts (with spring w , ~ners), the upper middle bolt
is longer. Do not i:illy tighten the bolts at this
stage.
30
 LT230R TRANSFER GEARBOX 1371
167. Slide the dog sleeve onto the rear of the output
shaft ensuring that the selector groove in thc dog
sleeve is to the front.
168. Compress the differential lock selector shaft
spring, and fit it between the sclcctor fork lugs.
169. Locate the selector fork inside the side cover
aperture in the housing engaging the groove in the
dog sleeve on the output shaft.
170. Fit the differential lock selector shaft into the
housing from t h e back, grooved (detents) end
last, and pass it through the selector fork lugs and
spring and into the front of the housing.
171. Rotate the selector shaft until the two flats are
uppermost.
172. Compress the spring slightly between the fork lugs
and fit the two locating ‘C’ caps.

17.5 &

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STll79M

Reassem bly
180. Fit new ‘0’ rings to the finger housing and
selector finger and lubricate with oil.
181. Locate the selector finger in thc finger housing.
182. Fit the differential lock lever over the flats on the
selector finger so that it will face forward in the
173. Fit the selector shaft detent ball and spring via t h e operating position.
tapped hole in the top of t h e housing. 183. Fit the plain washer and a ncw Nyloc nut.
174. Apply Loctite 290 to the detent plug threads, 184. Fit t h e differential lock ‘finger’ housing assembly
screw in the detent plug until the spring is just coil into the round aperture in the front output shaft
bound, then back off two complete turns. housing locating the selector ‘finger’ on the flat on
175. Loosely fit the differential lock switch in the t h e selector shaft inside the housing.
tapped hole on top of the housing, leaving t h e 185. Apply Loctite 290 to the ‘finger’ housing screw
locknut loose for adjustment. threads and fit the three securing screws (with
176. Grease and fit the differential lock selector side spring washers) to the correct torque.
cover gasket and fit the side cover, securing it with 186. Grease and fit the differential lock selector side
the seven bolts (with spring washers). cover gasket and fit the side cover, securing it with
t h e seven bolts (with spring washers).
Differential lock finger housing -Overhaul 187. Using a screwdriver inside the housing move the
high/low selector shaft rearwards (i.e. into high
(Instructions 177 to 183) range position) to provide access for fitting the
yoke over the end of the selector shaft.
Dismantling 188. Locate the yoke on the selector shaft, apply
iociiie 290 to the yoke set screw and fit iitc screw
177. Remove and discard thc Nyloc n u t and release the to the specified torque.
lock lever and selector ‘finger’ from the ‘finger’
housing.
178. Remove and discard the ‘0’ rings from the
selector finger and the selector finger housing.
179. Clean remaining parts, examine for wear or
damage, renew as necessary.
31
 LT230R TRANSFER GEARBOX

210. Fit the oil seal into the front of the transfer box
208 192,199 194,198 191.197 (seal lip to rear of case) using replacer tool
18G1422.
211. Prop up the transfer box on the bench with rear
side uppermost.
212. Drift in the input gear front bcaring track from
inside the back of the transfer box, using a
suitable punch.

Highllow selector housing -Overhaul

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(Instructions 189 to 205)

Dismantling
189. Remove the selector fork grub screw completely.
190. Rcmove the cross shaft retaining circlip.
191. Withdraw the cross shaft from the selector
housing with the operating arm attached.
192. Lift out thc sclcctor fork from the housing.
193. Remove the two ‘0’rings from the cross shaft.
194. Remove the operating arm from the cross shaft by Input gear -Overhaul
rcmoving the retaining set scrcw.
(Instructions 231 to 237)
195. Clean parts ensuring that all traces of Loctite are
removed, examine for wear or damage, renew as Dismantling
necessary.
213. Clean all parts, examine for wear and damage,
Reassembling renew as necessary. Remove the bearings only if
106. Fit the ‘0’ring to the operating arm end of the they are to be renewed.
cross shaft. 214. Secure hand press MS47 in vice and using collars
197. Locate operating arm o n the shaft blind hole. and buttons 18647-7 remove the front taper roller
198. Apply Loctite 290 to the operating arm set scrcw bearing from the input gear assembly.
threads and fit the set screw. 215. Reverse input gear assembly in hand press and
199. Locate t h e selector fork inside the housing. rcmove the rear taper roller bearing.
200. Slidc the cross shaft into the housing passing it 216. Remove the hand press from the vice.
through the selector fork.
201. Fit thc ‘0’ ring to the fork end of t h e cross shaft
(inside the housing) and lubricate both ‘0’rings.
202. Position the cross shaft fully home.
203. Locate the selector fork on the shaft blind hole.
204. Apply Loctite 290 to the fork grub screw threads
and fit the grub screw.
205. Fit the circlip on the end of the cross shaft.
206. Grease and fit the gasket to the highhow selector
housing aperture on the front output shaft
housing.
207. Position the highhow selector housing so that the
projecting selector fork engages the yoke side pins
inside the housing. ST1184M II I
208. Fit the six selector housing retaining bolts (with Reassembly
spring washers). -\ ;
;”
209. Prop up the transfer box on the bench with front 217. Locate thc front taper roller bearing on t h e input
side uppermost. gear assembly and press the bearing fully home.
32
 LT230R TRANSFER GEARBOX (371
*.rr:-.
c,+::,'i3 218. Repeat above procedure and fit the rear taper 229. If the reading obtained is outside the above
pzq roller bearing. limits the original shim must be changed
219. Lubricate both bearings with oil. accordingly.
220. Fit input gear assembly into the transfer box from 230. Remove the two screws retaining the mainshaft
t h e rear (gear end first). bearing housing.
231. Press out the rear bearing cup from the bearing
Obtaining bearing pre-load - with intermediate gear housing and remove and discard the original shim.
cluster removed 232. Select a shim to the required thickness to obtain
t h e correct pre-load of 0,02 to 0,07 mm (0.001 to
221. Secure the mainshaft bearing housing in the vice. 0.003 in) on reassembly.
222. Press out the rear input gear bearing cup and 233. Fit the shim to the main bearing housing and then
remove the shim behind it. press the rear bearing cup into position.
223. Clean the main bearing housing and measure 234. Fit the main bearing housing and tighten the two
original shim, noting its thickness. securing screws to the specified torque.
224. Fit the original shim to the main bearing housing. 235. Grease and fit P.T.O. cover gasket and finally fit
225. Locate the rear bearing cup on the main bearing the P.T.O. cover securing it with six bolts (with
housing and press it fully home. plain washers) to the specified torque.
226. Apply grease to the gasket and fit onto the Intermediate gear assembly -Keassembly
- ..
;Y!!:!.
t ransfcr box casing .
2-27. Fit the main bearing housing and tighten the two
236. First I-emovc the needle roller bearings and spacer
from the gcar assembly.
......

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. ..,
securing screws to the specified torque.
I

, . 1.

237. Clean the parts, including the thrust washers and

lock plate and examine for wear or damage,
renew as necessary. Refer to DATA at end of
section for thrust washer thickness.
238. Fit the '0'ring to t h e intermediate shaft.
239. Fit the '0' ring into the front of t h e transfer case.
240. Lubricate thrust washers, bearings, shaft and
spacer.
241. Fit needle bearings with spacer interposed.
If the bearings have plastic cages, the flangcd cnd
of each cage must face the thrust washers, when
fitted.
242. Fit front thrust washer to slot in transfer (plain
side to case).
243. Locate gear assembly partially into the transfer
case so that it rests on the front thrust washer.
244. Locate rear thrust washer (plain side uppermost)
into slot in transfer case.
. .i ..,
.I

.,.. ..
... 245. Gently push gear assembly into mesh.
. ...
. I .

246. Using a screwdriver through the intermediate

shaft hole guide the locating tab on the rear thrust
washer into the slot provided in the transfer case.
247. Align gear and thrust assembly and slide the
intermediate shaft into the transfer box from the
rear.
248. Align the shaft so that the lock plate slot in the
end is on top.

228. Wind sllfficienr striflg around the gear !W!h (0

rotate the input gear. A pull of 1,4 to 3,6 Kg ( 3 to
8 Ib) is required on the spring balance. This
applies to new or used bearings.
. ?..../. .
.I....

,. '.?,
NOTE: The pre-load can only be measured while
the Transfer gearbox is separated from the main
gear box.
El LT230R TRANSFER GEARBOX

249. Apply Loctite 290 to the lock plate bolt threads. Differential lock switch adjustment
Locate lock plate into position and fit securing
bolt (with spring washer). 257. Select differential locked position by moving the
differential lock lever towards the right side of the
transfer box.
258. Obtain a battery and connect a test lamp circuit to
the differential lock switch.
259. Slacken the lock nut off and screw in the lock
switch until the bulb is illuminated.
260. Turn the lock switch another half turn and tighten
the lock nut against t h e housing.
261. Disconnect t h e battery and move the differential
lock lever towards the left side of the transfer box
to disengage the differential lock.

257,261 259 258-

\ \ I

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250.- Using a screwdriver via the bottom of the transfer
case lift up the gear assembly and measure the
end-float with feeler gauges. This should be
between 0,08 and 0,35 mm (0.003 and 0.014 in).

Highhow gear change housing -Overhaul

(Instructions 262 to 298)

Dismantling
262. Remove the split pin from the clevis pin at the top
251. Grease and fit the bottom c w e r gasket. of the differential lock cross shaft lever which
252. Apply Loctite 290 to the ten bottom cover fixing secures it to the gear change cross shaft.
bolts only. 263. Remove the washer and clevis pin and the anti-
253. Clean and fit the bottom cover, using the t e n bolts rattle nylon strip.
(with spring washers). 264. Mark the position of the high/low gcar change
operating arm on the splined shaft of the gcar
Transmission brake assembly change crank arm.
265. Slacken the clamp bolt and remove the operating
254. Clean brake backplate and oil drip plate and arm.
apply silicone rubber sealant. Locate the 266. Remove the four bolts from the top of the gear
backpiate on the rear output shairispeedometer change housing and iift off the grommet piate
housing so that the brake operating lever is on the grommet, gate plate and gasket.
right-side rear. 267. Remove the split pin from t h e gear change crank
255. Fit the four Brako Durlok bolts, the lower two arm clevis pin and remove the clevis pin.
with plain washers, also retain the oil drip plate. 268. Remove the circlip from t h e highilow gear change
Tighten to specified torque. lever bush.
256. Clean and fit brake drum and fit the two 269. Withdraw the gear change lever from the housing,
countersunk retaining screws. with ball and socket bush.
34
 LT230R TRANSFER GEARBOX

..-::..
c.
. Reassembiy
I
..... ......~
I
I,:

279. Fit the two ‘0’rings to the housing end cover.

280. Fit the two ‘0’rings to the gear change crank arm.
281. Lubricate ‘0’rings with oil.
282. Clip the detent spring onto the detent plate.
283. Fit detent plate assembly into housing and retain
from outside with two Nyloc nuts (with plain
washers).
284. Compress thc detent spring and fit the gear
change crank arm in the housing.
285. Fit cross shaft into position locating end in the
crank arm.
286. Fit the housing end cover to support the other end
of the cross shaft.
287. Finally secure the housing end cover with the two
countersunk screws.
288. Before refitting the gear change lever remove the
clevis pin bushes and the Nylon socket bush and
ball.

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289. Clean all parts, examine for wear o r damage,
renew as necessary.
290. Fit and grease gear lever ball and Nylon socket
bush to gear lever.
291. Fit and grease clcvis pin bushes.
292. Locatc gear change lever assembly in cross shaft
270. Rcmove the two countersunk screws from t h e (do not fit socket bush retaining circlip at this
housing end cover. stage).
271. Remove the housing end cover. 293. Align gear change lever end with crank arm fork
272. Remove the two ‘0’rings from the end cover. ensuring that the gear lever is crankcd rcarwards
273. Remove the cross shaft from the housing. and fit clcvis and split pin.
274. Compress the detent spring and remove t h e gcar 294. Finally secure Nylon socket bush with circlip.
change arm from inside the housing. 295. Grease and fit gasket to gear change housing face.
296. Fit the gate plate.
297. Fit the grommet.
298. Fit the grommet plate and retain with the four
securing bolts (with spring washers).

275. Remove t h e two ‘0’rings from the crank arm.

276. Remove and discard the two Nyloc nuts retaining
the detent plate.
277. Remove the detent plate and spring from the
housing.
278. Clean all parts, examine for wear or damage,
renew as necessary.
35
 137I LT230R TRANSFER GEARBOX

299. Before refitting the high/low connecting rod and 320. After adjustment return the gear change lever to
gear change operating arms remove the respective the high range position.
clevis pins and Nylon bushes. Clean and examine 321. Remove the four bolts retaining the gate plate and
for wear or damage, renew as necessary. refit the grommet and grommet plate.
300. Grease and fit the Nylon bushes to the high/low 322. Refit the four bolts (with spring washers).
selector and gear change opcrating arms.
301. Assemble both operating arms to the connecting * On early versions of the transfer gearbox a different
rod with clcvis pin, plain washer and split pin. connecting rod fork end was used with a single
302. Slacken the gear change operating arm clamp bolt locknut. In this case the following method of
and fit the operating arm on to the splined shaft adjustment is recommended.
projecting from the high/low gear change
housing, carefully aligning it to the marks on both
(a) Disconnect the top of the differential lock
camponents.
cross shaft lever from the gear change cross
303. Tighten the clamp bolt to the specified torque.
304. Before refitting the differential lock cross shaft shaft.
lever and pivot bracket remove the respective (b) Remove the four bolts retaining the gear
clevis pins and Nylon bushes. Also remove the change housing to the remote gear change
split pin retaining the cranked lever and housing on the main gearbox.
disconnect it. Clean and examine for wear or (c) Lift up the housing assembly (with the
damage, renew as necessary. connecting rod attached) and rotate it as
II

305.- Fit the cranked lever to the bottom of thc cross required to vary the length of the connecting

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shaft lever and secure with a new split pin (with rod.
plain washer).
Transfer box mounting - Refitting
NOTE: Early gearboxes were fitted with a short
connecting link secured by a ‘Nyloc’ nut. 323. Fit the rubber mounting plate to the right sidc of
the front output housing by fitting the four
306. Grease and fit t h e Nylon bushes to the middle securing bolts (with new lock tabs).
pivot of the cross shaft lever.
307. Fit the cross shaft lever to the (loose) pivot Handbrake linkage -Refitting
bracket with the clevis pin, washer and split pin.
308. Fit the cross shaft lever fork (top) to t h c gear 324. Locate the handbrake linkage bracket in position
change cross shaft. on the right hand side of the transfer box casing
309. Locate the anti-rattle Nylon strip and fit the clevis and secure as follows.
pin, plain washer and split pin. 325. Fit the two bolts (with spring washers) and
310. Fit the cranked lever, at thc bottom of the distance pieces to retain the front sidc of the
differential lock cross shaft lever, to the lock lever linkage bracket.
and retain the clevis pin and plain washer with a
new split pin.
311. Grease and fit the Nylon bushes to the operating
arm on the selector housing cross shaft.

Adjustment of highllow connecting rod

312. This operation is carried out in situ or on the
bench, after assembly to the main gearbox.
313. Remove the four bolts from the top of the gear
changc housing and lift off the gear changc lever
grommet plate and the gcar change lever
grommet. Replace the four bolts tcmporarily to
retain the gate plate in position.
314. Check that t h e gear lever does not foul t h e gate ST
plate when high or low range is selected. If
adjustment is required carry out the following
procedure. 326. Fit the two bolts (with spring washers) to secure
315. *Slacken off the connecting rod locknuts. the rear end of the linkage bracket. The lower
316. Move gear change lever into high range bolt is shorter.
(rearwards) and move the operating arm on the 327. Insert the clevis pin through the brake operating
selector housing cross shaft into high range lever, fit the handbrake link, plain washer and
(forwards). split pin.
317. Tighten locknut(s).
318. Check that the gear change lever does not foul the .:/
gate plate in this position.
319. Engage and check low range in the same way.
36
 LT230R TRANSFER GEARBOX (371
.:'.
.- DATA
.......
.
:
.
I

;.::
.,.......
L
./..,, ..
..-!:
....
Input shaft bearing pre-load .................................. 0,02 to 0,07 mm (0.001 to 0.003 inch)
Intermediate gear end-float .................................. 0,08 to 0,35 mm (0.003 to 0.014 inch)
Intermediate gear thrust washer thickness ................ 2,?0 to 2,75 mm (1.06 to 1.@8in)
Centre differential rolling resistance - (minus
intermediate gear cluster and output shaft flange) ...... 1,8 to 4,5 Kg (4to 10 Ib) pull
Input gear rolling resistancc - (minus
intermediate gear cluster) ..................................... 1,4 to 3,6 Kg (3 to 8 Ib) pull
Differential pinions backlash ................................. 0,02 to 0,07 mm (0.001 to 0.003 inch)
Output shaft bearing pre-load ............................... 0,02 to 0,0? mm (0.001 to 0.003 inch)
Low range gear end-float
High range gear end-float ..................................... 0,05 to 0,15 mm (0.002 to 0.006 inch)
High range gear/bush running clearance diameter ...... 0,03 to 0,09 mm (0.0012 to 0.0035 inch)

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<" ,

37
 371 LT 95 FOUR SPEED GEARBOX

REMOVE LT 95 FOUR SPEED GEARBOX WITH When removing the chassis cross-member, do not allow
INTEGRAL TRANSFER BOX - ONE TEN V8 it to fall. Aftcr removing the fixings, use a spreader on
MODELS the chassis side members to free the cross-member.

Service tools: Remove the cover plate from the front lower half of the
RO 1001 - Lifting bracket for gearbox. A hydraulic or bell housing.
mechanical chassis spreader is also required.
Remove the clutch slave cylinder from the bell housing.
The gearbox should be removed from underneath t h e
vehicle using a suitable lifting hoist. Number 3 , chassis Position the transmission hoist under the gcarbox and
cross-member is removable to allow easy removal of support it.
the gearbox. Release the t w o rear gearbox mounting brackets from
the chassis side mcmbers.
WAKNING: It is essential, because of the considerable
weight and offset position of the centre of gravity of the
Support the engine under the sump.
gearbox, that a hydraulic transmission hoist of adequate
Pass the safety chain around the gearbox and make
strength and stability is used. Failure to observe this
fast.
precaution could result in the hoist tipping over and
Remove the bell housing bolts (eight bolts).
causing serious personal injury or damage to the
gearbox.
Withdraw the gearbox from thc engine. I -a

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Suitable hydraulic lifting equipment ( A ) is made by Fit the lifting bracket R O 1001 to facilitate any t. d s

Blackhawk International Limited. A special adaptor subsequent removal from the transmission lift.
plate (B) is produced by Claydrum Engineering
Services for holding the Land Rovcr V8 gearbox. This After refitting the gearbox i n t o the vehicle, refill the
adaptor plate can be used with various transmission main and transfer gearboxes with the correct grade oil,
hoists provided they meet the safety requirements to the oil level plug hole.
indicated above.
For further information regarding the hydraulic
transmission hoist and the special gearbox adaptor
plate, please contact the equipment manufacturers
direct. Their addresses are as follows:-

Transmission Hoist -type 67556 (T-3)

Blackhawk Automotive Limited
Brookfield Industrial Estate
Leacon Road
Ashford
Kent, England
Tclcphonc: Ashford (0233) 32151
Telex: 965621 BLUK G

Gearbox Adaptor Plate -type DS RT

Claydrum Engineering Services
P . 0 . Box 5
Clayland Avenuc
Worksop, England
Remove Tclcphone Worksop (0909) 4802 1

Gear change levers.

Central section of exhaust system.

Disconnect
Handbrake and speedometer cables.
Front and rear propeller shafts from the gearbox.
Vacuum pipes and electrical leads from differential
lock actuator.
Electrical leads from reverse light switch.
Make any remaining disconnections and note t h e
following important points during removal.
38
 LT 95 FOUR SPEED GEARBOX 1371
OVERHAUL LT 95 FOUR SPEED GEARBOX
The following overhaul instructions assume that the
gearbox is removed from the vehicle and the oil drained.

Remove the clutch slave cylinder, release mechanism

and bearing assembly, stand the gearbox on a wood
block on the bell housing end.

REMOVE AND OVERHAUL SPEEDOMETER

DRIVE HOUSING
1. Remove the brake drum retaining screws and
withdraw the drum.
2. Remove the four bolts retaining back plate,
remove oil catcher and back plate assembly.

11. Drive out the rear output shaft, using a hide mallet
on the threaded end.

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12. Slide off the spacer and speedometer worm.

ST1025M

13. Withdraw the oil shield.

14. Prise-out the oil seal.
15. Remove the circlip.
16. Tap out the ball bearing race.

3. Remove the eight bolts and withdraw the

speedometer drive housing.
4. Remove the speedometer spindle housing.
5
d. Y... V I . L..V .A..."..
b--. -..- "r-*---.
1 ift niit the driven o p a r and cnindlr
6. Take off the '0' ring seal.
7. Remove the thrust washer.
8. Withdraw the oil seal.
. .. ::,-.
.".. 9. Remove the locking n u t , using a flange tool,
.. :. .:.
. - ., ..,
.. washer and felt seal, output coupling flange to
output shaft.
10. Withdraw the coupling flange complete.
39
 LT 95 FOUR SPEED GEARBOX

ST1204M I #

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Check differential pre-load Assemble the housing
This check must be carried out if a replacement 23. Fit the rear output shaft ball bearing and circlip.
speedometer drive housing is to be fitted. The check is 24. Press in the output coupling flange oil seal, open
also required if a replacement gcarbox, differential unit face first, until the seal plain face just clears the
or diffcrcntial unit bearing- is being- fitted. chamfer on the seal housing bore.
17. Measure and record the thickness of the new joint 25. Fit the oil shicld, which must be a close fit on the
washer for the speedometer drive housing. speedomcter housing.
18. Offer the spcedometer housing, less joint washer. 26. Fit t h e speedometer worm I'ollowed by the spacer.
to the gearbox. 27. Fit the rear output shaft.
19. Measure the clearance between the drive housing 28. Fit the coupling flange.
and gearbox joint faces. This must be 0,lO to 29. Fit the felt seal, plain washer and locking nut to
0,15 mm (0.004 to 0.006 in) more than the secure the output flange and tighten to the correct
recorded thickness of the new joint washer. With torque.
the gasket fitted and the bolts tightened to 3 kgf.m 30. Assemble the following parts to the speedometer
(22 Ibf.ft) a final rolling'resistancc check should be spindle housing:
made using a spring balance and string wrapped 31. Fit the oil seal.
round the differential case. The resistance should 32. Fit the thrust washer.
be 14-16 Ibs (6-7 kg). The differential lock must be 33. Fit a new '0' seal.
# %i
disengaged to allow free rotation of the unit whilst 34. Fit the speedometer driven gear and spindle. w,. '.I
. ."I

making this chcck. 35. Fit the speedometer spindle housing assembly to
20. T o adjust the joint face clearance, adjust the the drivc housing.
thickness of shimming fitted behind the rear
bearing outer face as follows: instructions 21 and Assemble speedometer drive housing to gcarbox
22.
21. Drive out the bearing outer race. 36. Place a new joint washer in position.
22. Withdraw the shim washer and selcct a 37. Offer the drive housing to the gearbox and engage
replacement of the required thickness. Shim the rear output shaft splines in the differential unit.
thickness range is 1,65 to 2,80 mm (0.065 to 38. Position the flat on the drivc housing adjacent to
0.110 in) in 0,05 m m (0.002 i n ) stages. the flat on the intermediate shaft.
39. Secure the assembly with eight bolts and evenly
tighten to the correct torque.
40. Fit back plate assembly.
$1. oil catcher and with 'dyiosii,
42. Tighten special bolts to 55 to 60 Ibf.ft (75 to 80")
noting t h a t plain washers are fitted.

40
 LT 95 FOUR SPEED GEARBOX 1371
::‘:?2 REMOVE AND OVERHAUL MAINSHAFT REMOVE AND OVERHAUL INTERMEDIATE
c .
y.,
:.:,
+:...
~. I TRANSFER GEAR GEARS ASSEMBLY
Special tool: Special tool:
lSC1388 -mainshaft output gear puller R01003 -slave intermediate shaft
1. Remove thc mainshaft rear bearing housing. 1. Remove the speedometer drive housing.
2. Lift out the roller bearing. 2. Remove the gearbox bottom cover.
3. Remove the snap-ring. 3. Screw a suitable extractor into the 8 mm threadcd
4. Withdraw the shim washer. hole provided in the intermediate gear shaft.
5. The transfer gcar is retained on the splines with 4. Hold the intermediate gear cluster in position and
Loctite 275. Use a puller 1861388 to withdraw it. withdraw the shaft.
5. Insert the slave shaft R01003 to retain together the
NOTE: The roller bearing outer race is located by a roll gears assembly.
pin which must be punched-out before the race can be 6. Withdraw the intermediate gears assembly.
removed. 7. Slide the thrust washers, bearings and gears from
the slave shaft.
8. The input gear and outer member is a riveted
assembly and no dismantling is permitted.

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9. Remove the ‘0’ring seal from the intermediate
gear shaft.
10. Wash and degreasc all parts and inspcct for wear
and renew if necessary. When new, the thrust
bearing washers have a lead/tin coating, i f this only
has worn away there is no need to renew them.

Assembling Assemble intermediate gears

Fit the transfer gear to the mainshaft. 11. Place the slave shaft on the bench, extractor thread
Fit the shim washer and snap-ring. end uppermost.
Check the end-float between the shim washer and 12. Fit a pear-shaped thrust washer, inner ring and a
snap-ring. End-float to be 0,050 mm (0.002 in) thrust bearing washer to the shaft (ring grooved
maximum. Shim washer range 1,s to 2,O m m face downwards).
(0.071 to 0.079 in) in 0,05 mm (0.002 in) stages. 13. Fit a needle-roller bearing and the ‘high’ gear
Fit the roller bearing and rear bearing housing. (plain face first) to the shaft.
41
 LT 95 FOUR SPEED GEARBOX

-_ I

ST12 1 OM

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14. Position a thrust bearing washer on the ‘high’ gear.
15. Fit a spacer, nccdlc-roller bearing and a further
spacer to the input gear inner member. ST121
16. Position the assembled input gear on the shaft and
engage the lower spacer in the previously
positioned thrust bearing washcr. 20. When the foregoing bearing clearance check has
17. Locatc a thrust bearing washer over thc upper been completcd. slidc the gcars and slave shaft
spacer. assembly into the transfer gearbox and engagc thc
selector forks.
21. Withdraw the slave shaft and lubricate the bearings
through the shaft aperture.
22. Fit the intermediate shaft and ‘0’ ring seal with the
flat on the shaft toward t h e differential unit.
23. Measure the clearance between the rear thrust
washer and the gear casing. This must be 0,15 to
0,23 mm (0.006 to 0.009 in).
24. Adjustment is carried out by substituting one or
both of thc thrust washcrs. The washers are
available in 33.5 mm (0.139 in), 3,63 nini
(0.143 in) and 3,74 mm (0.147 in) thicknesses.
25. Refit the gearbox bottom cover.
26. Refit the speedometer drive housing.

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 1
ST1213M
and thrust washer (ring grooved face upwards).
42
 LT 95 FOUR SPEED GEARBOX

,.,?... ..*.. .
.c.
REMOVE AND OVERHAUL DIFFERENTIAL UNIT 11. Remove the casing securing bolts.
..... ..: ..
.'ti .'?

12. Lift off t h e rear case assembly (and oil retaining

Special tool:
ring - later gearboxes).
18G47BB - bearing extractor
13. Withdraw the side gear (and thrust washer - later
1. Select the differential lock. boxes).

-
2. Rcmove the differential lock actuator assembly 14. Slidc out the cross-shafts and rcmovc the bevel
3. Remove the front output shaft and housing. pinions and thrust washers from the front case
4. Remove the speedometer drive housing. assembly.
5. Remove the intermediate cluster assembly. 15. Withdraw the side gear (and thrust washer - latcr
6. Remove the differential assembly. boxes) to dismantlc the front case 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 18G47BB.

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

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Loct i tc.

ST1216M

NOTE: From gearbox numbers 1300 3481A and 1700

0007A the following modifications have been made to
the differential.
A. Introduction of side gear bushes.
B. Improved thrust washers.
C. Addition of thrust washer on side gears.
D. Modified cross pins.
E. Addition of oil retaining ring.
The new differential part number FRC 7740 is only
interchangeable with superceded unit part number 594
340.

ST1215M
I I
9. Remove the fixings, low-speed gear to casing.
10. Withdraw the gear.

43
ST1799M
 LT 95 FOUR SPEED GEARBOX

NOTE: If replacements are required, replace the Assemble differential to gearbox

following items 16 and 17 as sets.
27. Refit the differential unit.
16. Bevel pinions and side gears (set of six). 28. Refit the speedometer drive housing.
17. Cross-shafts (set of two). 29. Refit thc frofit output shaft and housing.
18. Check the gear teeth for damage. 30. Rcfit the diffcrential lock actuator assembly
19. Check all parts for satisfactory general condition
including the sidc gear bushcs. NOTE: If a replacement differential unit is being
fitted, carry out the ‘Differential hearing pre-load
NOTE: The differential case halves are a matched check’, described in ‘Speedometer drive housing -
pair, and halves must not be changed individually. Overhaul’.

Assemble differential
CAUTION: It is essential that during the following
assembly all components are well lubricated with new oil
of the correct grade.
REMOVE AND OVERHAUL TRANSFER GEAR
20. Fit a sidc gear into the rear casing. LEVER AND CROSS-SHAFT
21. -Fit a side gear into the front casing.

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22. Fit the bevel pinions, thrust washers and cross- 1. Remove the top cover.
shafts into the front casing. 2. Slacken the selector finger pinch bolt.
23. Fit thc rear casing to the front casing. Tighten the 3 . Drive out the retaining pin, gear lever to cross-
bolts evenly in sequence to thc correct torquc. Use shaft.
Loctite 275 on threads. 4. Withdraw the gear lever.
24. Offer the low gear to the differential casing. 5 . Withdraw the cross-shaft and spacer.
25. Align the fixing holes and fit the bolts evcnly in 6. Lift out the selector finger.
sequence to the correct torque. Usc Loctite 7. Remove the retaining plates.
26. Fit the roller bearings and refit the diffcrential unit. 8. Withdraw the scaling rings.

Assemble gear lever and cross-shaft

9. Position the selector finger in t h e gearbox.
ST121 10. Fit the cross-shaft and spacing collar and engage-i
the selector finger.
11. Fit the sealing ring and retaining plate at the R.H.
NOTE: If the differential case or bearings have been
side of the gearbox.
12. Fit the gear lever and retaining pin.
$5
*- ,/

replaced, carry out the ‘Differential bearing pre-

load check’.
44
 LT 95 FOUR SPEED GEARBOX 137(
13. Fit the remaining sealing ring and retaining plate. 12. Withdraw the two detent balls.
14. Tighten the selector finger pinch bolt. 13. Lift out the spacing rod and spring.
15. Select ‘High’ transfer range, that is, the larger 14. Remove the blanking plug.
intermediate gear engaged. 15. Withdraw the detent spring from the cross drilling.
16. Slacken the selector finger bolt.
17. Rotate the cross-shaft until the gear lever is
inclined 45 degrees to the vertical position.

W17
ACO

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ST 1219M 1 -

Assemble shaft and selectors

18. Tighten the selector finger pinch bolt. 16. Position the detent spring in t h e inncr bore in the
19. Fit the top cover using a new joint washer and cross drilling.
evenly tighten the retaining bolts. 17. Locate the detent ball on the spring.
18. Enter t h e selector shaft, push the ball against the
spring and push in the shaft.
19. Fit the detent ball, spring and spacing rod to the
vertical drilling.
20. Position thc rear selector fork, plain face to rear, in
the gearbox.
21. Position t h e front selector fork, extended boss to
the rear, in the gearbox.
. . ... 22. Align the retaining pin holes and engage the
.... .I...

.. .... ...
.,.. selector shaft in the selector forks.
REMOVE AND OVERHAUL TRANSFER BOX 23. Fit the retaining pin, front fork to shaft.
SELECTORS AND SHAFT 24. Set transfer gears in ‘Neutral’ position.
25. Adjust the rear fork position until there is 0,12 to
1. Remove the speedometer drive housing. 0,25 mm (0.005 to 0.010 in) clearance between the
2. Remove t h e transfer gearbox top cover. front face of the rear fork and the rear face of the
3. Select ‘Low’ range transfer gear. input gear inner member.
4. Drive out the retaining pin from the front selector 26. Tighten the rear fork pinch bolt.
fork sufficient to free the fork.
5. Ease the differential u n i t to t h e rear.
6. Push the forward selector fork forward on the
shaft.
7. Pull to the rear on the rear selector fork to move
the selector shaft out of engagement with t h e
detent balls in the casing rear face.
8. Remove the pinch bolt o n the rear fork.
9. Partially withdraw the selector shaft and lift out the
selector forks.
10. Remove the retaining pin from the front fork.
. .... .
1..

.h.,.
, .
. 11. Withdraw t h e selector shaft, closing the shaft
housing by hand to prevent the detent balls from
dropping into the casing.
45
 37 LT 95 FOUR SPEED GEARBOX

Overhaul assembly
0
&
5. Hold the output shaft in a vice or use a flange
restraining tool and remove t h e flange retaining
n u t and washer.
6. Withdraw the coupling flange complete with
mudshield.
7. If required, press off the mudshield.
8. Press out the shaft toward the rear.
9. Withdraw the oil seal.
10. Remove the circlip.
11. Withdraw the output shaft bearing.
12. Wash and degrease all parts, examine for wear and
renew as necessary.

27. Fit the blanking plug to the cross drilling.

28.-Fit the transfer box top cover using a new joint

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washer and evenly tighten the bolts to the correct
torque.
29. Fit the speedometer drive housing.

ST 1223M

RER E ND OVER€ IUL FRONT OUTPUT

SHAFT AND HOUSING Assemble output shaft assembly to housing

Remove output shaft assembly 13. Fit t h e output shaft bearing and secure with the
ci rcl i p.
1. Remove the differential lock actuator assembly. 14. Fit the oil seal, lip side towards the bearing.
2 . Remove the six retaining bolts, spring washers and 15. Press in the output shaft from the rear.
gasket. 16. Fit t h e coupling flange complete with mudshield ,
3 . Withdraw the output shaft and housing complete. and flange bolts. Secure with the locking nut to the
4. Lift o u t the lock-up dog clutch. correct torque.

46
 -b

LT 95 FOUR SPEED GEARBOX 37

REMOVE AND OVERHAUL BELL HOUSING AND REMOVE AND OVERHAUL GEAR CHANGE
CLUTCH RELEASE SELECTORS
I . Withdraw the locating staple from the clutch 1. Remove the bell housing.
release slecve and release lever. 2. Select neutral, remove the reverse light switch and
2. Lift out the release sleeve and bearing assembly. remove the gearbox top cover and joint washcr.
3. Remove the bell housing fixings and make a note 3. Lift out t h e dctent springs.
of the position of each bolt and nut. 4. Withdraw the detcnt balls, using a small magnet or
4. Withdraw t h e bell housing complete with clutch an air blast.
release lever. 5 . Slacken the pinch bolt securing the reverse selector
5. If required, remove the push rod clip and the finger.
spring clip and withdraw the clutch release lever. 6. Drive out the four retaining pins until the shafts are
free in the selectors.

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ST1225M

Assemble clutch release and bell housing 7. Tap out the selector shafts.
8. Withdraw the selector jaws and forks.
6. If removed, fit the release lever spring clip. 9. Withdraw the two interlock plungers from the
7. Apply a thin film of Unipart Universal or other cross-drilling.
suitable jointing compound around the three 10. Rcmove t h e lock-wired pivot bolt.
.. selector shaft holes in the bell housing rear face. 11. Lift out the reverse cross-over lever.
8. Fit the bell housing, locating on the dowels.
9. Apply a thin film of molybdcnum disulphide grease Overhaul
onto the front cover extension sleeve.
10. Fit thc rclcase sleeve and bearing assembly. Examine all parts and renew if worn. Renew thc detent
11. Fit the locating staple to the clutch reiease sleeve springs. Ensure that t h e retaining pins are an
and lever. interference fit, if not, renew.

..

ST 1

47
 1371 LT 95 FOUR SPEED GEARBOX

Assemble gear change selectors 26. Move the reverse shaft forward until the selector
jaw abuts the casing.
12. Withdraw the retaining pins from the selector jaws. 27. Holding the reverse shaft as described in the
13. Engage the cross-over lever and locate fully in the previous item, move the reverse selector finger
groove in the reverse idler with the peg in the top forward on the shaft until it abuts the casing, then
of the cross-over lever fully in the selector finger. move it rearward until it is just clear of the casing.
14. Start the pivot bolt in the lever threads. Should it 28. Place a 0,25 mm (0.010 in) feeler gauge between
not start properly move the lever away from the the upper edges of the reverse and third/fourth
selector finger but not out of engagement with the selector jaws.
idler.
15. Locate the first/second gear selector fork in the NOTE: The edges of the selector jaws taper slightly,
groove in the outer member, with the boss on the therefore, it is important that the feeler gauge is
fork to the rcar. Position the boss to the R.H. side positioned between the upper edges.
of the box.
16. Locate the third/fourth gear selector fork in the 29. Hold the reverse and third/fourth selector jaws
groove in the outer member. Position the fork with together to retain the feeler gauge, then rotate the
the retaining pin entry hole at the top R.H. side. reverse selector finger until it abuts the third/fourth
17. Fit the third/fourth gear selector shaft and selector shaft and tighten the pinch bolt.
interlock pin assembly and secure to the selector
. fork with a retaining pin.

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18. Fit the two interlock pins to engage in the grooves
each side of the third/fourth gear selector shaft.
19. Position the reverse stop hinge plate and selector
jaw in the gearbox, adjacent to the third/fourth
gear selector jaw.
20. Fit the reverse gear selector shaft and engage the
selector jaw and hinge spring.
21. Push the shaft home and engage the reverse cross-
over lever selector finger. Do not secure the pinch
bolt at this stage.
22. Secure t h e revcrse gear selector jaw to the shaft
with a retaining pin.

24 23
A+-
2
a01 15 25
+*

30. Wire lock the cross-over lever pivot bolt.

31. When fitting the hinge spring to the reverse stop
hinge, first engage t h e large hook around the
selector shaft, as illustrated, before fitting the small
hook to the reverse stop hinge pin.

ST 1227M

23. Posi!i~n thp first,/secogd b-"'

up?ir cplprtnr Jiaw in the
"w'--'Va

gearbox.
24. Fit the first/second gear selector shaft; engage the
selector jaw and selector fork as the shaft is pushed
home.
25. Fit the retaining pins, fitting the rear pin first.

48
 LT95 FOUR SPEED GEARBOX (371
6. Lift out the reverse idler gear assembly.
7. Remove the circlip and plain washer.
8 Lift out the needle rollcr bearings and further plain
washer.
9. Withdraw the remaining circlip.

32. Fit the detent balls and springs.

T
33. Selcct neutral and using a new joint washer, fit thc

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gearbox top cover and secure with the eight bolts,
STl23 1M
and evenly tighten to the correct torque.
34. Fit the reverse light switch
35. Fit the bell housing.
Assemble reverse idler gear and shaft
10. If removed, fit the shaft support bush, using
Locquic primer grade ‘Tand ‘AVV’ grade.
11. Fit the circlip to selector groove end of thc gcar.
12. Fit thc plain washer and two needlc rollcr bearings.
13. Fit the outcr plain washcr and secure with circlip.
REMOVE AND OVERHAUL REVERSE IDLEK 14. Fit a new ‘0’ring seal to the idler gear shaft.
GEAR AND SHAFT 15. Offer the idler shaft to the gearbox and align the
retaining bolt holes.
Special tool:
16. Smear clean gearbox oil onto the ‘0’ring seal.
18G1335 -extractor for shaft
17. Position the reverse idler assembly in the casing. .
1. Remove the gearbox sidc cover. 18. Engagc thc sclcctor foot in the idler gcar groove.
2. Remove the gearbox bottom cover. 19. Drive in the idler gear shaft until t h e retaining bolt
3. Remove the bolt securing the idler gear shaft in t h e holes are aligned.
gearbox casing. 20. Before fitting the retaining bolt, trcat the threads
4. Withdraw the idler gcar shaft, using cxti-actor with Locquic primer grade ‘T’ and allow to dry.
18G1335. Then, fit thc bolt using Loctite Studlock grade.
5 . Remove the ‘0’ring seal. 21. Fit the gearbox bottom cover using a new joint
washer and secure with the fourteen bolts evenly
tightening to the correct torque.
22. Using a new joint washer fit the side cover with the
four bolts and tighten to thc spccificd torque.

49
 LT 95 FOUR SPEED GEARBOX

REMOVE AND OVERHAUL FRONT COVER AND

OIL PUMP
Service tools:
R01005 -Centralising tool
18G134 - guide and
18G134DG - assembly tool for fitting oil seal and oil
feed ring.

1. Lift out the retainer staple from the clutch release

bearing assembly and t h e release lever. See clutch
release overhaul.
2. Withdraw the release bearing assembly.
3. Remove the slave cylinder pushrod. -
4. Remove the spring clip. STl234M
5 . Withdraw the clutch release lever.
6. Remove the front cover assembly, complete with
oil pump joint washer.
7. Remove the shim washer located between the front 16. Press in the oil feed ring, using 18G134 guide and
cover and thc layshaft front bearing. 18G134DG adaptor.

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17. Fit the ball, spring and plug. When fitted, the plug
must be flush with, or not more than 0,25 mm
(0.010 in) below the front cover rear face.
18. Fit the oil pump ring gear.

ST1235M N

Overhaul
8. Remove the pump cover gasket and oil pump
drive.
9. Withdraw the oil pump ring gear.
10. Remove the oil feed ring.
11. Withdraw the oil seal.
12. Remove the plug and withdraw the ball and spring
from the relief valve housing.
13. If required, drift off the extension sleeve. Fit a
repiacemenr using iocrite 275 grade.

Reassemble
14. Press in the oil seal, plain face first, using 186134
guide and 186134DG adaptor. ST1236M
15. Align the centre hole of three in the oil feed ring
with the oil delivery hole in the front cover.
50
 LT 95 FOUR SPEED GEARBOX (37(
Fit cover assembly to gearbox

19. Position the layshaft bearing shim washer.

20. Position the front cover assembly and loosely fit
the fixings.
21. Fit the oil pump drive gear to engage the drive
square in the layshaft.
22. Fit the oil pump cover and joint washer and fit the
fixing screws and washers and carefully tighten to
the correct torque.
23. Fit the gauge R01005 to align the primary pinion
with the bell housing.

-
24. Visually check that the front cover is concentric
about the primary pinion. Adjust the front cover
position about its fixings to suit.
ST1238M

Assemble bearing plate assembly

NOTE: To replace a bearing plate, a bearing plate and

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gearbox casing mated assembly must be fitted.

10. Locate the cone i n t o the third/fourth-speed

synchromesh unit.
11. Lubricate the oil tube, using clean gearbox oil.
12. Position the joint washer.
13. Engage the layshaft with the primary pinion and
ST1237M front bearing outer member.
14. Fit the bearing plate and layshaft.
15. Align the bearing plate with the gearbox casing and
slide home the dowel sleeves.
16. Refit the studs. Smcar Loctite 'Studlock' grade
25. When satisfactory, tighten the front cover fixings. CVX, on t h e two upper studs securing threads
26. Fit the clutch release lever and spring clip. before fitting.
27. Fit the slave cylinder push-rod. 17. Fit the oil pump drive gear.
28. Fit the release bearing assembly. 18. Using a new joint washer fit the oil pump gear
29. Fit the retainer staple to the clutch release bearing cover.
assembly and lever. 19. Fit the bell housing.

REMOVE AND OVERHAUL BEARING PLATE

ASSE MB LY
1. Remove the bell housing and position the gearbox
with the front end uppermost.
2. Remove the oil pump gears cover and joint washer.
3. Withdraw the oil pump drive gear.
4. Temporarily remove the four fixing studs from the
gearbox front face.
5 . Ease the bearing piate away from the gearbox.
6. Withdraw the two dowel sleeves which locate the
bearing plate.
7. Withdraw the bearing plate assembly complete
with primary pinion and layshaft.
8. Withdraw the joint washer.
9. Withdraw the layshaft.
51
 LT 95 FOUR SPEED GEARBOX
~ ~~~ ~ ~~ ~

REMOVE AND OVERHAUL PRIMARY PINION Assemble primary pinion

1. Remove the bell housing. 9. Check that the orifice drilkd in the oil tube is clear.
2. Remove the front cover and oil pump assembly. 10. During refitting, take care to avoid damage to the
3. Remove the bearing plate assembly. oil tube. Rotate the shaft in the bearing to ensure
4. Remove the circlip. that the oil tube is straight.
5. Lift off the shim washer. 11. Support the bearing plate using suitable wooden
6. Press out the primary pinion. blocks. Position the blocks across the bearing
housing aperture to act as assembly stops.
12. Press in the bearing until flush with the bearing
plate.
13. Press in the primary pinion. Check that the bearing
remains flush with the bearing plate.
14. Fit the retaining plates and serrated bolts.
15. Fit the shim washer and circlip.
16. Measure the clearance between the circlip and the
shim washer. There must be a clearance of
0,05 mm (0.002 in) maximum.
17. If required, adjust the clearance by fitting a
replacement shim washer. Shim range is 2,O to ,

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2,15 mm (0.079 to 0.085 in) in 0,05 mm (0.002 in)
stages.

ST 1 240M

7. Withdraw t h e bearing retaining plates and serrated

bolts.
8. Press out the primary pinion bearing.

18. Fit the bearing plate assembly.

19. Fit the front cover and oil pump assembly.
20. Fit the bell housing.

52
 LT 95 FOUR SPEED GEARBOX 1371
__ ..-..._
,.~
.,
-.
...,.
. .. ...
.
.1-. REMOVE AND OVERHAUL THE MAINSHAFT
.,..-..
..L

. .,
.....,. ASSEMBLY

Special tool:
1861388- extractorfor mainshaft spacer and gear
1. Remove the bell housing.
2. Rcmove the front bearing plate.
3. Remove the main gearchangc sclectors.
4. Removc the mainshaft rear bearing housing and
roller bearing.
5. Remove the bottom cover from the transfer
gearbox.

NOTE: At this stage in the dismantling, on early

gearboxes only, it is necessary to remove the transfer top
cover selector finger and shaft. On later gearboxes the
cross-shaft is machined to enable the spacer to be 1 I . Withdraw the mainshaft assembly, allowing the
completely withdrawn. Also the main shaft spacer and first-speed gear to remain behind to avoid fouling
transfer gear are secured by Loctite 275 to the main on thc casing.
shaft. 12. Lift out the first-speed gear.

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6. Remove the snap-ring, shim washer and mainshaft
transfer gear, using special tool 18G1388.

7. Fit extractor 1861388 to transfer gear spacer. 13. Refit thc first-speed gear, scalloped thrust washer,
8. Withdraw the spacer along the mainshaft until the thrust needle bearing and stepped thrust washer,
larger diameter on the spacer reaches the transfer stepped face outwards.
gear lever cross-shaft. 14. Withdraw the mainshaft spacer.
9. Withdraw the spacer through thc machined
scollop.
10. When the spacer is free on the mainshaft removc
the extractor.

.'.. "4..
I.! .;::"
ST1246M

53
 LT 95 FOUR SPEED GEARBOX

Overhaul mainshaft assembly Assemble

Dismantle 22. Replacement thrust washers and roller bcarings

must not be degreased.
15. Withdraw thc first-speed gear, thrust washers and 23. Lubricate all items before assembly, iising clcan
roller bearings from the rear of the shaft. main gearbox oil.
16. Remove the snap-ring and shim washer from thc 24. Fit the oil seal to the mainshaft front end.
front of the shaft.
17. Lift off the third/fourth gears synchromesh Assemble synchromesh units
assembly.
18. Withdraw the third and second-speed gears and the 25. Fit together the thirdfourth gcar synchromesh
associated thrust washers and needle-rollcr outer and inner members, outer member coned
bearings. face toward inner member plain face.
19. Dismantle the third/fourth gears synchromesh 26. Fit the sliding blocks, radius face outward.
assembly, first pushing down the sliding blocks to 27. Locate the springs through the sliding blocks into
free the synchromesh balls from the retaining the housing bores in the inner member.
groove in the outer member. 28. Position the balls on thc spring ends; press home in
sequence and retain by hand.
29. Lift the outer member to retain the balls. Continue
lifting until the balls spring home into the annular ~-~
4.L.

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groove in the outer member.
30. Assemble the first/second gear synchromesh unit in
the manner dcscribed for third/fourth gear unit. Fit
the outer member coned face toward the front end
29- of the mainshaft.

Assemble mainshaft front end

31. Fit a synchromesh cone to the firstkcond gcar
synchromesh outer member.
32. Position a chamfered thrust washer, a thrust needle
2'1 bearing and a scalloped thrust washer on the
mainshaft.
33. Fit a radial needle bearing and the second-speed
gear.

ST1247M

20. Dismantle the firsthecond gears synchromesh

assembly in a similar manner, particularly noting
their position for refitting.
21. Withdraw the oil scal from the Sore in the
mainshaft front end.

ST1249M
-2w

ST 1248M

54
 LT95 FOUR SPEED GEARBOX 137
.. ,..,
' .,..
34. Fit a scalloped thrust washer, a thrust needle
-r . .,':. 5.
. ,.'-.:.....:': bearing and a further scalloped thrust washer.
35. Fit a radial needle bearing and the third-specd
gear.
36. Fit a scalloped thrust washer, a thrust needle
bearing and a further scalloped thrust washer.
37. Position a synchromesh cone onto the third-speed
gear.
38. Fit the synchromesh unit, coned face to rear.

Assemble mainshaft rear end

46. Fit a synchromesh cone to the first/second gear
synchromesh outer member.
47. Position a chamfercd thrust washer, a thrust needle

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bearing and a scallopcd thrust washcr on the
mainshaft.
48. Fit the first-speed gear and bearing.
49. Fit a scalloped thrust washer, a thrust needle
bearing and the stepped thrust washcr, stcppcd
face outwards.
50. The mainshaft spacer, transfer gear, shim washer
and snap-ring are fitted during mainshaft refitting.

ST1253M

Set end-float of gears

39. Position the mainshaft asscmbly vertical, front end
uppermost.
Assemble mainshaft assembly to gearbox
40. Apply a light loading on the gears to remove
end-float. 51. Position the gearbox with the R.H. side
41. Position the snap-ring in the mainshaft groove. rfownwar& to .id refittifin
6'
42. Measure the distance between the snap-ring lower 52. Remove the gearbox side cover.
edge and the synchromesh unit inner member. 53. Temporarily move the first-speed gear toward the
43. Select a shim to reduce the measured clearance to rear of the shaft.
0,025 to 0,150 mm (0.001 to 0.006 in) when fitted. 54. Offer the assembled mainshaft to the gearbox and
44. Shim range is 1,85 to 2,45 mm (0.073 to 0.096 in) manoeuvre the first-speed gear past the reverse
in 0,15 mm (0.006 in) increments. idler gear.
45. Fit the selected shim washer and the snap-ring.
55
137I LT 95 FOUR SPEED GEARBOX
~~

55. Engage the shaft into the main bearing.

56. Engage the first/second gear synchromesh outer
65. Temporarily remove the snap-ring and the
mainshaft transfer gear.
fl
e....+I
;v
member and the reverse idler gear. 66. Slide back the mainshaft spacer as far as the
57. Push the mainshaft home enough to allow the transfer gear lever cross-shaft will allow.
mainshaft spacer to be locatcd on the rear end, 67. Apply a thin coating of Loctite 275 grade to the
with the spacer larger diameter forward of the exposed area of the mainshaft.
transfer gear lever cross-shaft. 68. Push home the mainshaft spacer.
69. Fit the mainshaft transfer gear.
70. Fit the previously selected shim washer and secure
with the snap-ring.
71. Fit the bottom cover to t h e transfer box using a
60 new joint washer and evenly tighten the fourteen
retaining bolts to the correct torque.
72. Fit the mainshaft rear bearing housing and roller
bearing.
73. Assemble the main gearchange selectors to the
gearbox.
74. Fit the front bearing plate.
75. Fit the bell housing.

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58. Re-position the first-speed gear, thrust washers
and thrust needle bearing correctly on the
mainshaft. REMOVE AND OVERHAUL LAYSHAFT BEARINGS
59. Push the mainshaft fully home, ensuring that t h e Special tools:
thrust washers and needle bearing remain correctly R01004 -extractor mainshaft spacer
located against the first-speed gear. 18G284 - extractor and 18G284AR - adaptor,
60. Move the mainshaft spacer along thc shaft, and extractor layshaft rear bearing outer member
into the oil seal, to abut the main bearing. 18G47 - Press and 1SG47BA - Collars, extractor for
61. Temporarily fit the mainshaft transfer gear. layshaft bearing inner members
62. Position thc snap-ring in the groove in the
mainshaft. 1. Remove the bell housing.
63. Hold the mainshaft fully to the rear and measure 2. Remove t h e front cover and oil pump assembly.
the clearance between the snap-ring and the 3. Remove the main gears selectors. gy..
%
;
transfer gear. 4. Remove the front bearing plate assembly.
;r

64. Select a shim washer to allow 0,050 mm (0.002 in) 5. Remove the mainshaft assembly.
maximum clearance between the snap-ring and 6. Press out the layshaft front bearing outer member
transfer gear when fitted. Shim range 1,8 to from t h e front bearing plate.
2,O mm (0.071 to 0,079 in) in 0,OS mm (0.002 in)
increments.

3
ST 1256M

56
 LT 95 FOUR SPEED GEARBOX 37
,:.:.:.. 7. Extract the layshaft rear bearing outer member 12. Press the rear bearing outer member into the
i *
:
.
. :..:!
"...
...
I.
,:
..,;
1

from the gearbox casing, extiaetor 186284 and gearbox casing.

adaptor 18G284AR. 13. Enter the front bearing outer member into the
front bcaring plate. DO not fit fully in at this stage.

. ST1259M I J

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8. Withdraw the bearing inner members from the 14. Remove the primary pinion from thc bearing plate.
layshaft. Extractor 18647 press and 18G47BA 15. Position the layshaft in the gearbox casing.
col tars. 16. Temporarily fit the front bearing plate and joint
washer.
n 17. Press in the front bearing outer member until thcrc
is no end-float on the layshaft and no cnd-load on
the bcarings.
18. On the bearing outer member position a shim
washer of a thickncss suitable to stand 0,25 m m
(0.010 in) approximately proud of the front
bearing plate. This shim thickness may be
subsequently adjusted depending on the amount of
bearing pre-load it affords.
19. Temporarily remove the oil pump top cover and
withdraw the pump drive gear.
20. Temporarily fit the front cover and new joint
washer to the bearing plate. Ensure that the shim
washer remains in position.

ST 1258M

Check bearing pre-load

8. Repiacement bearings inner and outer membcrs
are supplied as matched pairs and not as separate c
items. /-

10. The replacement bearings must not be degreased.

Before fitting, lubricate with correct grade gearbox
oil. Refer to lubrication chart.
11. Press the bearing inner members onto thc layshaft.

57
 37 LT 95 FOUR SPEED GEARBOX

21. Measure the rolling resistance of the layshaft, using REMOVE AND OVERHAUL DIFFERENTIAL LOCK
a spring balance and a cord coiled around the ACTUATORASSEMBLY
layshaft larger diameter. The rolling rcsistance
must be 7 to 3,38 kg (6 to 7.5 Ibs). 1. Remove the four bolts and withdraw the assembly
from front output shaft housing.
2. Remove the detent spring and ball.

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22. To adjust the pre-load, fit a replacemcnt shim or
suitable thickness to the front bearing outer
member. Shim range is from 1,55 mm (0.059 in) to
2,510 mm (0.098 in) in 0,05 mm (0.002 in)
increments. Dismantle and overhaul assembly
23. When the pre-load is satisfactory, remove thc front
cover assembly. 3. Remove thc differential lock warning switch and
24. Remove the front bcaring plate. washers.
25. Fit the primary pinion. 4. Drive out the retaining pin.
26. Fit the oil pump cover and drive gear. 5 . Remove the actuator fixings.
27. Fit the front bearing plate assembly. 6. Withdraw the actuator and shaft.
28. Assemble the selectors for the main gears. 7. Withdraw the '0' ring seal.
29. Fit the front cover and oil pump assembly. 8. Withdraw the joint washer.
30. Fit the bell housing.

9. Fit a new '0' ring seal to actuator shaft.

10. Coat both sides of the joint washer with Hylomar
PL32M.
11. Fit the actuator and shaft and secui-c to the
housing.
12. Fit thc actuator shaft retaining pin.
13. Fit the diffcrential lock warning switch and
washers.

Assemble to gearbox
14. Fit the ball and detent spring.
15. Apply Hylomar PL32M jointing compound to both
sides ot a new actuator housing joint washer.
16. Fit and secure the assembly to the gearbox and
evenly tighten the four retaining bolts.

58
 LT 95 FOUR SPEED GEARBOX 37 L

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Renew

Renew 3 . Start the engine and move the differential lock

vacuum control valve to the ‘up’ position.
3 . Engagc reverse gear. 4. Connect the elcctrical leads to the actuator switch.
4. Connect the electrical leads to t h e switch. 5 . Screw in the switch, less shim washers, until the
5 . Switch the ignition ‘ON’. switch contacts are made.
6. Screw in the switch, less shim washers, until the
switch contacts are madc.
7. Screw in a further half turn.
8. Mcasurc the clearance bctwcen the switch lower
face and the gearbox.
9. Select shim washers to suit the clearance. Shim
thicknesses are 0,5 m m (0.020 in) and 0,127 m m
(0.005 in).
10. Fit the sclected shim washcr(s) and switch. Tighten
to a torque of 1,4 to 2,0 kgf m (15 to 20 Ibl lt) (20
to 27 Nm).

ST 1265M

6. Screw in a further half turn.

7. Measure the clearance between the switch lower
face and the housing.
8. Select shim washers to suit the clearance. Shim
thicknesses are 0,5 mm (0.020 in) and 0,137 m m
(0.005 in).
9. Fit the selected shim washcr(s) and the switch.
10. Re-position control valve and stop engine.
59
El LT 95 FOUR SPEED GEARBOX
RENEW REAR OUTPUT SHAFT OIL SEAL Renew

Remove 7. Press in the oil seal, open face first, until the seal
plain face just clears the chamfer on the seal
1. Disconnect the rear propeller shaft at the housing bore.
transmission brake. 8. Fit the oil shield, which must be a close fit on the
speedometer housing.
9. Fit the oil catcher, applying Bostik compoiind 771
\ ' \
to seal the oil catcher against the brake back plate.
\' 10. Fit the transmission brake drum complete with rear
\
'\ '
coupling flange.
'%
'\, 11. Fit the oil seal washer and locking nut and tighten
to the correct torque.
\
\ 12. Connect the rear propeller shaft to the
transmission brake.

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ST1266M
\

RENEW FRONT OUTPUT SHAFT OIL SEAL

2. Remove the locking n u t , washer and the felt oil
seal. Remove
3 . Withdraw t h e transmission brake drum complete 1. D~~~~~~~~~ the front propeller shaft.
with rear coupling flange. 2. Remove the coupling flangc locknut and washer.
4. Remove the oil catcher. 3 . Withdraw the coupling flange complete with
5. Prise off the oil shield. mudshicld.
6. Withdraw the oil seal. 4. Withdraw the oil seal.

STl268M

Renew

'I 5 . Fit thc oil seal, lip side Icading.

ST1267M
6. Fit the flange coupling with mudshield.
7. Secure the flange with locknut and washer and /-:.
tighten to the correct torque.
8. Connect the propeller shaft.
$x ,;
60
 LT85 FIVE SPEED GEARBOX El
REMOVE LTWLT230T MAIN GEARBOX AND Cradle for removing gearbox
1 TRANSFER BOX
The gearbox should be removed from underneath the
vehicle, using a hydraulic hoist, as illustrated; a cradle
for locating the gearbox on to thc hoist can be
manufactured to the drawing below. If a similar cradle
was made for the LT77 gearbox, it can be modified to
suit both the Ll77 and LT85 gearboxes by making the
modifications shown by the large arrows.
Manufacture a cradle to t h e dimensions given in the
drawing and attach it to a transmission hoist. To
achieve balance of the transmission unit when mounted
o n the transmission hoist, it is essential that point A is
situated over thc centre of thc lifting hoist ram. Drill
fixing holes R to suit hoist table. Secure the
transmission unit to the lifting bracket at point C, by
mcans of the lower bolts retaining t h e transfer gearbox
rear cover.

* Refer to the Removal instructions for the LT77

gearbox page 1. The method for removing the LT8Y

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LT230T gearbox assembly is similar, except for the
following.
1. It is not necessary to remove the engine fan cowl.
2. Remove the air cleaner.
3. Remove thc highhow selector housing from the
transfer box.
4. Use t h e cradle and hydraulic hoist already
described, to remove the gearbox.

NOTE: It may be necessary to remove the

ST1547M
transmission brake drum to allow removal of the
8.75 gearbox assembly.

1.0 x 1.0 x 0.13

230x250~30
\
-*
. $0.19
5.0

3.0
76 .O
1
f
0.25

508.0

MATERIAL AND WELDING SPEClFlCATlON AVANT

VORDER LT85
..
..
.
.

ST 538M
102.0
Steel Plate
Tu be
BS 1449 (Grade 4 or 14)
BS 4848 (Part 2 )
Arc Welding BS 5135
ANTERIORE

e = MODIFICATION

61
 )371 LT85 FIVE SPEED GEARBOX

OVERHAUL LT85 FIVE SPEED GEARBOX

-Ninety and One Ten V8 models

Service Tools:
18G 1294 - Guidestuds
18G 1400 -Two legged puller
1% 1431 -Replacer, mainshaft bearings
MS 284 -Slide hammer
MS 550 -Driver handle
LST 101 - Gauge, first gear end float
LST 102 -Remover-Replacer, mainshaft rear oil seal
LST 284-1 -Adaptor-Remover, reverse idler shaft
LST 550- I - Adaptor-Remover-Replacer, layshaft
front bearing roller
LST 550-2 - Adaptor-Remover-Replacer, layshaft rear
bearing outer track
LST 550-3 - Adaptor-Remover-Replacer, mainshaft
front and rear bearing
LST 1431-1 - Remover-Replacer, front plate and

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mainshaft
In addition to the above Service Tools, the following
five items should be manufactured locally to facilitate
dismantling and reassembly of the gearbox.

ST1369M

Selector detent spring retaining tool and spaccrs.

A - Spacers can be madc up from washers

ST1476M

Spacer for retaining layshaft rear bearing

ST1371M
ST1475M

Spacers for retaining front bearing plate. Two required.

Gauge for reverse cross-over lever adjustment.
A -This dimension must be more than 12 mm.

62
 LT85 FIVE SPEED GEARBOX 137

1
. ~

..
, ...

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ST1321M

Stand for securing the gearbox in a vice

A. 11 mm diameter holes
R . Make from 50 mm x 6 m m stcel angle
C. Make from 6 mm steel plate
D. 10 mm diameter bolt with hexagonal head
E. 10” nuts

MATERIAI, AND WELDING SPECIFICATION

Steel Plate BS 1449 (Grade 4 or 14)
Arc Welding BS 5135

63
 LT85 FIVE SPEED GEARBOX

GEAR CASINGS
1. Bell housing and clutch release assembly
2 . Oil pump assembly
3 . Front bearing plate
3 . Main gear case
5 . Oil filter assembly
6. Gear change lever assembly
7. Extension housing m

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64
 I
. .. .,. I -
<.
ri.':~i.$:
. . . .. . .., , ,
.
. .-...:
...?.. ,3
1.
A.

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GEAR SELECTORS
1. Selector rails
2. Selector fork assembly for 5th gear
3. Selector arm for reverse gear
4. Selector fork for 1st and 2nd gear
5. Reverse gear cross-over lever assembly
6. Selector fork for 3rd and 4th gear
7. Selector jaws
 LT85 FIVE SPEED GEARBOX

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A--

\L-

66
 -
LT85 FIVE SPEED GEARBOX 37
I 1 ' 'l. I
GEARBOX DATA

Mainshaft first speed gear running clearance 0,075 mm maximum

Mainshaft third spccd gcar running clearance 0,075 mm maximum
Mainshaft fifth speed gear running clearancc 0,075 m m maximum
Input shaft bearing running clcarance 0,075 mm maximum

DISMANTLING Bias spring housing and gear lever

1. Ensurc gearbox oil has bcen completely drained. 10. Remove four bolts and spring washers and lift bias
2. Position gearbox on bench and support with spring housing from gearbox.
suitable wooden block. 11. Remove bias springs and shims. Care should be
3. Remove four bolts and detach L.H. gearbox taken w h e n removing lower shims to avoid them
mounting bracket. slipping under gear lever pivot bar and into
4. Remove extension housing and gasket. gearbox.
5. Fit manufactured stand to gearbox and secure with 12. Removc bias spring housing gasket.
two bolts, nuts, spring and plain washers. Adjust 13. Remove gear lever, complctc with gaitcr and nylon
bolt under filter housing as necessary. cup.

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10

12
c
LI
ST1322M
11
13
6. With assistance, fit gearbox and stand into a
suitable vice and firmly sccurc.
7. Removc six bolts and washers and lift bcll housing,
complctc with clutch release lever, sleeve and
thrust bearing, lrom gearbox.
8. Remove bell housing gasket.
9. Fit two bell housing fixing bolts, with spacers to
front bearing plate.

ST 1318M

Gearbox top cover

14. Remove reverse light switch, if fitted.
15. Remove breather pipe banjo union fixing bolt.
16. Remove eight bolts and spring washers and lift top
cover and breather pipes from gearbox.
17. Remove detent springs.
ST1323M 18. Remove top cover gasket.
67
 1
7 LT85 FIVE SPEED GEARBOX

Selector rails and forks 22. Remove clamp bolt from reverse cross-over lever
and withdraw reverse selector rail and jaw from
19. Using a suitable magnet withdraw the selector rail gearbox.
detent balls from drillings in gearbox. If detent 23. Remove split pin washer and clevis pin securing 5th
balls arc tight leave operation until after selector gear selector rail to selector fork and bracket
rails have been withdrawn, when the detcnt balls asscmbiy.
can be pushed down into the selector rail borc, 24. Push selector rail forwards and tap down 5th gear
then removed. jaw roll pin until jaw is free on rail.
20. Release reverse gate spring from knock-over lever 25. Withdraw 5th gear selector rail and j a w from
and remove from reverse gear rail. gearbox.
21. Raise knock-over lever and tap down reverse jaw 26. Remove clamp bolt from 3rdi4th selector fork and
roll-pin until jaw is free on rail. move selector rail forward.

20

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I

I .

ST1324M

68
 LT85 FIVE SPEED GEARBOX 37
,: ..:
-...
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,.
': ;$
.. 27. Tap down 3rd/4th jaw roll pin until jaw is free on 36. Remove two bolts, spring washers and plain
.:: .-,.
.._ji ' selector rail. washers securing 5th gear fork and bracket
28. Withdraw 3rd/4th selector rail and jaw. assembly to gearbox. Do not displace selector fork
20. Remove interlock from 3rd/4th sclcctor rail. slipper pads when removing fork.
30. Tap down lst/2nd jaw roll pin until .jaw is free on
sclector rail.
31. Remove clamp bolt from Isti2nd selector fork and
withdraw lst/2nd selector rail and jaw.
32. Remove interlock from lst/2nd sclcctor rail.
Kevcrsc idlcr shaft, mainshaft and layshaft
33. Lift rcverse cross-over lcvcr rrom gearbox.
34. Remove 1st/2nd and 3rd/4th selector forks. 37. Remove circlip, selective washer, oil seal collar and
'0' ring from mainshaft.

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ST1328M 37
35. Remove interlock plungers and also dctcnt balls if
not removed in operation 19.

I I
ST1329M

STI 38. Remove 5 t h gear synchro hub and baulk ring.

39. Remove 5th gear, spacer, needle roller bcaring and
thrust washer.

ST1330M 39
69
E[ LT85 FIVE SPEED GEARBOX

43. Disengage 1st and 4th gears.

44. Remove two socket hcad set screws and two bolts
0
’*
7..::.

with spring washers and remove reverse shaft and

layshaft bearing track retaining plate.
4.5. Remove reverse lcver pivot bolt and lift reverse
40 lever from gearbox.

40. Remove mainshaft rear bearing circlip.

41. Release stake nut collar from recess in layshaft,
remove stake nut and 5th gear from layshaft.

NOTE: To facilitate this operation lock gearbox by

45 $3:
..;,

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i. .
I..
engaging both 1st and 4th gears. a&&.

ST1334M

46. Fit extractor adaptor Tool N o . LST 284-1 to

reverse idler shaft.
47. Fit slide hammer Tool No. MS 284 to adaptor and
withdraw reverse idler shaft from gcarbox. Reverse
idler gear and thrust washer will drop into bottom
41 of gearbox.
48. Kcmove seven bolts and spring washers and

ST1332M e withdraw front cover and gasket from front bearing

plate.

42. Fit manufactured spaccr to layshaft to retain rear

bearing and secure in position with stake nut
finger-tight only

42
ST

70
 LT85 FIVE SPEED GEARBOX I37 I
49. Remove layshaft front bearing spacer.
50. Remove input shaft bearing circlip and selective 56
washer.
51. Remove bolts and spacers retaining front bcaring
plate to gearbox. 57

50
58. Extract mainshaft from rear bearing. To facilitate
operation assistance will be needed to support
mainshaft and layshaft.
59. Tap layshaft forwards and remove rear bearing
race.
60. Withdraw mainshaft and layshaft assemblies.

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61. Remove rcvcrsc idler gear and thrust washer from
gearbox.
ST1336M

52. Fit plates and spacers of' Tool N o . LST 1431-1 to

front bcaring plate with 90 mm bolts.
53. Locate two legged puller Tool N o . 18G 1400 as
shown and remove front bcaring plate from input
shart and gearbox.

NOTE: Centre bolt and lcgs of puller must be

aligned squarely with input shaft.
OVERHAUL

Main gearbox case

52,
1. Remove drain plug.
2. Remove retaining plug and oil filter.
3. Remove filler/level plug.
4. Remove interlock cross drilling plug.
53

ST1337M

<A
J7.
D y m n . r p ha.,&na7
.\L.III"*b "bU11116
r\l,,tP Iy.Ic.Lyt
Y1ULb 6 U J R " ' .

55. Remove stake n u t and spacer from layshaft.

56. Fit plates and spacers of Tool No. LST 1431-1 to
rear of gearbox with 95 mm bolts in top locations
and 90 mm bolts in lower.
57. Locate two legged puller Tool No. 18G 1400, again 5. Remove top cover location dowels and 5th gear
ensuring centre bolt and legs of puller are aligned fork bracket dowels, if necessary.
squarely. 6. Remove gearbox stand.
71
 37 LT85 FIVE SPEED GEARBOX

7. Position gearbox on suitable wooden blocks and 12. Clean mainshaft and layshaft bearing seatings.
remove mainshaft rear bearing using Tool Nos. 13. Clean rcverse gear idler shaft seating, drain plug,
LST 550-3 and MS 550. and level/filler plug tappings.
14. Using an air line blow out filter plug tapping and
oil-way, detcnt and interlock seatings.
15. Clean top cover facc and 5th gear fork bracket
dowels.
16. Hcat gearbox case to facilitate fitting of mainshaft
rear bearing and layshaft bearing track.
17. Fit circlip to mainshaft rear bearing.
18. Position rear bearing in gearbox seating.
19. Using Tool Nos. LST 550-3 and MS 550 tap rear
bearing into position.

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8. Remove rear bearing circlip and clcan. 1 9 1
9. Using Tool Nos. LS'T 550-2 and MS 550 remove
layshaft rear bearing outer track.

NOTE: Use rounded end of tool.

ST

20. With gearbox still warm fit layshaft rear bearing

outcr track using Tool Nos. LST 550-2 and MS 550.
21. Refit interlock drilling plug.
22. Refit lcvel/filler plug - d o n o t tighten at this stage.
23. Refit oil filter and retaining plug using new copper z;:.,,
,..,e.-
:
washer. .. .,
24. Refit magnetic drain plug and new copper washer.

20

STl341 M

10. CIea earbox case asket faces, in erior and

exterior and inspect for cracks and obvious signs of
damage etc.
11. Clean magnetic drain-plug, oil filter retaining plug,
level/filler plug and oil filter. ST1343M

72
 LT85 FIVE SPEED GEARBOX 37
Front bearing plate 9. Using Tool No. 550-1 fit layshaft bearing, with
6,5-7 mm of bearing protruding from front of
1. Support front bearing plate on suitable wooden bearing plate. This allows easier assembly of the
blocks as shown. layshaft and mainshaft at a later stage.
2. Using Tool Nos. LS'I' 550-3 and MS 550 remove
input shaft bearing.

. 2
ST1347M

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10. Fit circlip to input shaft bearing.
11. With the front bearing plate still warm fit input
shaft bearing, using Tool Nos. LST 550-3 and MS
550.
ST1344M

3. Remove circlip from bearing.

4. Remove layshaft front bcaring from bearing plate
using Tool N o . LS'I'550-1.

ST1346M

ST1345M

5 . If necessary, replace bearing plate dowels.

6. Clean bearing plate, gasket forces and input shaft
and layshaft bearing seatings.
7. Using an air line blow out oil-way in bearing plate.
8. Heat front bearing plate to facilitate refitting of
input shaft and layshaft bearings.
73
 37 LT85 FIVE SPEED GEARBOX

Front cover and oil pump Gearbox extension housing

1. Remove cover plate, drive gear and impellor gear. 1. Remove rear oil seal from extension housing using
2. Remove cover plate ‘0’ring. suitable drift.
3. Position wooden blocks under front cover and 2. If necessary, replace extension housing dowels.
remove oil feed ring and oil seal. 3. Clean gasket faccs and interior and extcrior
surfaces.
4. Using Tool No. LS7’ 102 fit new oil seal to
ex t e n sio n ho usi ng .

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W
ST1348M

4. Clean all front cover componcnts.

5. Lubricate lip o f new oil seal and position in front
cover seating with close side downwards.
6. Fully seat oil seal in position using suitable tube.
7. Fit oil feed ring, ensuring the three holes of the l o p Cover
feed ring are at the bottom and the ccntrc hole is
aligned with the mating oil pump feed drilling in 1. Clcan top cover gasket faccs and interior and
the front cover. exterior surfaces.
6 . Fully scat feed ring in position using suitable tube. 2. Remove top filler plug, clcan, apply sealant and
9. Fit cover plate ‘0’ring, lubricate and fit impellor refit plug.
gear, and drive gear.
10. Fit cover plate, ensuring chamfer of centre hole is Bias spring housing and lower gear lever
facing towards oil pump. 1. Fit housing to vice and remove bias spring
adjusting Screws r1 d

STl350M

2. Clean lower gear levcr and nylon cup.

3. Clean housing, adjusting screws, bias spring bores,
springs and shims. _-.
w: “$1’

4. Refit bins spring screws - two turns only at this

stage.
74
 LT85 FIVE SPEED GEARBOX 1371
f. I. . ,s Bell housing lstl2nd synchro assembly
;.:?:,*i
_!..
'
.,,
. 7. ,.
1 . Remove clip retaining thrust bearing carrier to Before dismantling
clutch opcrating lever f o r k .
2. Withdraw thrust bearing and carrier assembly from 1. Before dismantling, mark relationship of synchro
sleeve. hub to sleeve.
3. Remove bolt and spring washer securing operating 2. Fit synchro baulk rings.
lever pivot clip to lever. Remove pivot clip. 3 . Place synchro assembly and baulk rings into a
4. Remove operating lever and pivot slotted washer. plastic bag t o ensure none of the components are
5. Remove operating lever pivot. lost during next operation.
6. Unscrew single bolt and remove bearing sleeve 4. Press sleevc from hub.
from bell housing.
2

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ST1352M
STl351M
5. Retrieve synchro balls, springs and slipper pads
and remove baulk ring.
7. Rcmovc bearing sleeve dowels, if necessary.
6 . Clean all synchro assembly components.
8. Clean bell housing interior, exterior and mating
faces. NOTE: Before reassembling the synchro assembly,
9' grease to lever pivot and inner face O f carry out the checks for 3rd and 2nd gear end floats, as
bearing carrier. described in the following paragraphs under the heading
10. Reassemble in rcverse order. 'Mainshaft and gear train'.
Input shaft 7. Fit synchro hub to sleeve ensuring the alignment
1. Remove 4th gear baulk ring and needlc roller marks match up.
bearing. 8. Place hub and sleeve over suitable block.
2. Clean all components, ensuring oil-way on input 9. With hub resting on block adjust height of hub
shaft is blown through with air line. sufficiently to f i t springs.
3. Clcan input bearing circlip and selectivc washer. 10. Locate slipper pads, fit springs and press balls
down to be retained by synchro sleevc.
Mainshaft 11. Fit baulk ring to hub and sleeve.

1. Remove shim and 1st gear bush.

2. Remove 1st gear, needle roller bearing and bearing
spacer.
3. Remove 1st gear baulk ring, lst/2nd gear synchro
assembly and 2nd gear.
4. Remove 2nd gear baulk ring, 2nd gear, needle
roller spacer and needle roller bearing.
5 . Fit mainshaft into vice and remove circlip retaining
3rd/4th synchro hub and gear assembly.
6. Remove selective washer, 3rd/4th synchro - I

assembly and baulk ring.

7. Remove 3rd gear, needle roller spacer and needle ST1477M 16
roller bearing. 12. Invert synchro assembly, carefully, and fit second
8. Remove oil seal from front of maimhaft. baulk ring.
9. Clean mainshaft, and all mainshaft components 13. Press synchro sleeve over hub to locate balls in
and check for obvious wear. Ensure oil-ways in position.
mainshaft are blown through with air line. 14. Remove baulk rings.
75
 b

37 LT85 FIVE SPEED GEARBOX

3rdl4th synchro assembly

1. Repeat operation as for IstRnd synchro assembly

(omitting the gear end float checks).

NOTE: When reassembling 3rd/4th synchro the

large chamfer on synchro slceve faces the small boss
on the hub,

5th gear synchro assembly *2

I . Repeat operation as for Ist/2nd synchro assembly. STl354M

NOTE: When reassembling 5th gear synchro the Next fit the original selective washer and retain
chamfer on the hub faces to the rear. with the circlip. Check the clearancc between the
washer and the synchro hub which must not exceed
Mainshaft and gear train 0,075 mm (.U03 in). The condition is ideal when
the selective washer can be just turned by hand,
3rd gear end float i.e. minimum end float. Finally secure components
with a new circlip.
1. Locatc the main shaft in a vertical position as

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shown. Fit 3rd gear and needle roller bearing to the Oil seal
shaft and replace the 3rdl4th synchro inner
member. Press down on the synchro inner member 3. Renew oil seal in the front of the main shaft at this
and check thc gear running clearance with a feeler stage then invert the shaft ready for assembly of the
gauge, as shown. A clearancc in excess of 0,19 mm rear end.
(.U08 in) indicates that the thrust laces arc w c r n
and may be the cause of gear noise or transmission 2nd gear end float
back lash. New or little worn components will
4. Fit 2nd gcar needle roller bearing, spacer, 2nd gear
usually have a clearance of between 0,075 mm and
and synchromesh inner member with thc selector
0,125 mm (.003 in to .OM in).
groove towards the rear as shown. Press down on
the synchro inner member and check 2nd gear end
float tolerance which is identical to 3rd gear
previously described.

ST1539M I I

ST

3rdl4th synchro end float

2. Maintain the mainshaft in a vertical position as
shown. Fit 3rd gear needle roller bearing, spacer,
3rd gear, baulk ring and synchromesh with the
large area thrust face towards 3rd gear and the
chamfer on the outer member towards thc front.
76
 ~ 8 E S5PEED G E A RB O X
~ FIV 1371
....
.....,-;..:
,.:i 1st gear to bush end float 5th gear end float
i.; .:.
...
..:, ..:.?:,
, 7. Fit 5th gear thrust washer, 5th gear, needle bearing
5. To carry out 1st gear check, it is not necessary to and spacer followed by synchromesh unit but
assemble the components on to the mainshaft. leaving out the baulk ring at this stage. Press down
Assemble 1st gear on to the bush and using a on the synchro inner member and chcck the gear
suitable straight edge or flat plate (the oil pump end float as shown; this tolerance, again is identical
back plate is ideal) check the end float of 1st gear to 3rd gear.
on the bush as shown. The tolerance is identical to
3rd and 2nd gear end floats.

. .
. .

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I .

5th gear synchro end float

S7-1540M
8. Fit the 5th gear synchromesh backing plate, seal
collar, original selective shim washer and circlip.
Then check the clearance as shown; select a
suitable shim washer to minimise the clearance.
l s t h d synchromesh end float
?.
I his adjustment is identical to the lst/2nd and
3rd/4th synchromesh units.
6. Next fit the 1st gear baulk ring, 1st gear bush and With all t h c mainshaft adjustments correct, remove
gear, original selective washer, dummy bearing the 5th gear componcnts ready for assembly.
LST 101 and circlip onto the shaft, then check the
end float as shown. Choose a suitable selcctivc
shim washer to obtain the correct tolerance which
is identical with 3rd/4th synchromesh, i.e.
minimum to 0,075 mm (.U03 in).
. .. . .. .
.. .

.6

-6
5th gear selector fork and bracket assembly
1. Remove slipper pads from selector fork and check
STl353M for wear.
2. If necessary, remove circlips and remove selector
fork pivot pins.
3. Clean all componcnts and refit in reverse order.
77
 37 LT85 FIVE SPEED GEARBOX

Lay shaft REASSEMBLING GEARBOX

1. Remove layshaft rear bearing inner race. Input shaft, mainshaft and layshaft
2. Fit layshaft to vice and lever off front bearing inner
track. 1. Position front bearing p!ate on suitable stand and
fit input shaft into bearing.
2

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S'I

3. Clean layshaft, bearings and tracks and check for

wear. 2. Secure bearing plate in vice, fit original selective
4. Fit layshaft front bearing track. washer and retain with circlip.
5. Fit rear bearing race to layshaft, ensuring the 3. Measure the clearance between washer and input
identification numbers etc., of the bearing are shaft bearing. If a measurcmcnt in excess of
facing forwards. 0,075 mm is obtained remove circlip and washer.
NOTE: Inner tracks are offset and the bearings
must be fitted with narrow shoulders together.

Reverse idler gear assembly, shaft and lever

1 Secure reverse gear in vice and iemove circlip
retaining bearings

STl359M ST1357M

2. Remove upper thrust washer, two needle roller

bearings and lower thrust washer.
3. Invert reverse gear and remove second circlip. 3 . Selcct and measure new washer to takc up the
4. If necessary, -I C ~ I I U V- Cspiit piin and withdraw siipper excessive running ciearance.
pads and washer from reverse gear lever. 5. Fit n e w selective washer and retain with circlip.
5 . Press out reverse lever cross link operating pin, if 6. Recheck to ensure a running clearance of
necessary. 0,075 mm is obtained between washer and bearing.
6. Clean all components and check for wear. 7. Position front bearing plate on suitable stand. g-::
I . L

7. Lubricate needle roller bearings and reassemble 8. Lubricate mainshaft pilot bcaring and fit to input t., ,
,

reverse idler gear assembly and lever in reverse shaft.

order. 9. Fit 4th gear baulk ring to input shaft.
78
 LT85 FIVE SPEED GEARBOX 37
. ,.._
......
.
.. ,
,:,:.,i.',..
., ;-
10. Lower mainshaft assembly into input shaft at the 15. Fit guide studs 18G 1294 to gearbox.
., ...
,
same time rotating to engage baulk ring slots and
lugs.
I 1. Engage 3rd gear.
12. Fit layshaft assembly to front bearing plate and
mesh with mainshaft.

NOTE: Take care to ensure that the front layshaft

bearing rollers are not put out of alignment, then
return 3rdl4th synchro hub to neutral.

ia

-12
ST1361M

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Gearbox case and reverse shaft
16. Fit new gasket on front bearing platc.
17. Lower gearbox case over mainshaft/layshaft
asscmblics using guide studs to locate front bearing
plate.
18. Fit tube, Tool No. LST 1431-1 over mainshaft and
locate on rear bearing.
19. Fit Tool No. 18G 1431 over mainshaft and locate
12 on other tool.
20. With assistance, to prevent gearbox and mainshaft
rotation, and using above tools, pull gearbox to
ST1358M front bearing plate.

13. Remove the rear bearing circlip and dummy

1
.
..'
. bearing.

Reverse gear 19
14. Fit thrust washer to reverse gear, chamfer towards
gear, locate gear in gearbox case, and retain
temporarily in position with a screwdriver, or
similar implement.

.
8 /I7

J
I
@

ST1362M

79
 .
37 LT85 FIVE SPEED GEARBOX

21. Fit layshaft rear bearing (identification numbers to 35. Ensure oil pump drive aligns with the square
rear) dummy spacer, and rctain temporarily with seating in the layshaft and fit front cover to front
layshaft nut. bearing plate and secure with seven bolts and
22. Remove guide studs 18G 1294. spring washers.
23. Temporarily fit two bell housing bolts with spacers, 36. Removc tape from input shaft splincs.
to secure front bearing plate to gearbox.
24. Remove Tool Nos. 18G 1431 and LST 1431-1 and Reverse lever, reverse shaft/bearing retaining plate
then check that t h e mainshaft is engaged through
bearing sufficiently to fit mainshaft bearing circlip. 37. Fit reverse lever to reverse gear.
25. Remove screwdriver from reversc shaft location 38. Apply Loctite Stud and Bearing Fit (270) to pivot
and f i t reverse shaft. bolt threads, fit bolt in gearbox and locate in
reverse lever pivot boss.
39. Position reverse shaft, layshaft bearing track
retaining plate and secure top of plate with two
bolts and spring washers.

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39
26. Invert gearbox and fit spacer to layshaft front
bearing.
27. Using Tool Nos. LS’I‘ 550-1 and MS 550 locate
layshaft front bearing to final position.

40. Apply Loctite Stud and Bearing Fit (270) to socket

head set screws and secure bottom of retaining
plate.

5th gear, layshaft and mainshaft

41. Remove nut from layshaft and remove dummy
27 spacer.
42. Fit 5th gear to layshaft with large boss to the rear.
43. Rotate layshaft to give access to stake slot.
44. To facilitate next operation, lock gearbox by
engaging 1st and 4th gears.
45. Fit a new 5th gear retaining nut and tighten to the
specified torque.
46. Stake retaining n u t collar into recess in layshaft.
47. Return 1st and 4th synchros to neutral.
ST1364M
48. Fit mainshaft rear bearing circlip.
28. Temporarily remove layshaft bearing spacer. 49. Fit thrust washer.
29. Refit gcarbox stand (manufactured tool) to 50. Lubricate needle roller bearings and fit to
underside of gearbox and secure with two bolts, mainshaft followed by spacer and 5 t h gear.
nuts, spring and plain washers. Adjust bolt undes 51. Fit 5th gear synchro cone and synchro hub
filter housing as necessary. assembly.
30. Secure gearbox stand in vice. 52. Tape mainshaft splincs and f i t ‘0’ring to its seating
31. Check that 4th gear baulk ring and all other baulk on mainshaft.
rings are free. 53. Fit oil seal collar and locate in peg on hub backing
32. Fit layshaft front bearing spacer. plate.
33. Fit new gasket to front cover. 54. Fit the washer selected during the 5th gear end
34. Tape input shaft splines, to prevent damagc to float check and retain with circlip.
front cover oil seal in next operation. 55. Remove tape.
80
 LT85 FIVE SPEED GEARBOX 1371

Selector rails and forks 59. Fit l s t n n d and 3rd/4th selector forks.
56. Locate 5th gear fork and bracket on to synchro hub
and gcarbox dowels.
57. Secure fork bracket to gearbox with two bolts,
plain washers and spring washers.

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58. Fit selector rail intcrlock plungers into the cross-
drilling in the gcarbox case. 60. Fit reverse cross-over lever.
61. Insert interlock into l s t / h d selector rail.

81
 LT85 FIVE SPEED GEARBOX

62. Push M 2 n d selector rail through gearbox seating 68. Locate selector rail into 5th gear selector fork and
and locate in reverse cross-over lever and selector secure with clevis pin, washer, and split pin.
fork; do not tighten fork clamp bolt. 69. Fit roll pin and secure selector rail and jaw.
70. Push reverse sclector rail through gearbox scating
NOTE: IstiZnd fork clamp bolt is not a set boit. and locate in reverse cross-over. Do not lighten
lever clamp bolt.
63. Fit lst/2nd selector jaw to rail and align for roll pin. 71. Fit jaw to rail and align for roll pin.
64. Using suitable drift, tap in roll pin to secure jaw 72. Using a suitable drift, fit roll pin to secure sclccror
and rail. rail and jaw.
65. Repeat operation for 3rd/4th selector rail and jaw.
66. Push 5th gear selector rail through gearbox scating NOTE: The roll pin must be inserted sufficiently to
and locate in reverse cross-over lever. be flush with the underside face of the selector.jaw.
67. Fit 5th gear selector jaw to rail, align for roll pin.

72 71 I 73

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ST 1367M

82
 LT85 FIVE SPEED GEARBOX 137 I
73. Fit reverse gate spring to selector rail and knock- Reverse cross-over lever adjustment
.:,,..:,.~....,
:+.<:,!?
,
.,...:I. over Ievcr.
74. Fit detent balls and springs. The purpose of the following adjustment is to ensure
that when 1st gcar is selected the outer member of the
Selector fork adjustment Ist/2nd synchro mcmber is not also engaged with the
reverse idler.
75. Fit top cover gasket. 84. Move reverse gear thrust washer fully forward.
76. Secure detent spring retaining tool and spacers to 85. Fit gauge (manufactured tool) to selector shaft.
gearbox using two 8 x 50 m m bolts and plain 86. Move rail rearwards and select reverse gcar.
washers. 87. Move cross-over lever rearwards to lightly nip
gauge between reverse gear and thrust washer.
88. 'Tighten reverse cross-over lever clamp bolt and
return rail to neutral. Remove gauge.
89. Move l s t k n d rail rearwards and select first gear.
Ensure a minimum clearance of 1,0 mm has been
obtained between reverse gear idler and reverse
76 gear on lst/2nd synchro sleeve. If there is not
enough clearance, readjust the reverse cross-over
lever.
w
90. Return lst/2nd rail back to neutral.

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91. Remove detent spring retaining tool and spacers.
ST1368M

77. 'Tighten bolts and compress detent springs until

retaining plate contacts the two spacers.
78. Ensure that 1st/2nd selector rail and synchro slccve
arc in neutral position. Tighten clamp bolt
sufficiently to eliminate a n y rock in the selector
fork and move selcctor fork rearwards.
79. Scribc a pencil line on rail at rear of fork yoke.
80. Movc fork forwards on rail and scribe line on rail at
rear of fork yoke.
81. Scribe a line midway between the other lincs on the
selector shaft.
82. Move selector fork to centre line.and tighten clamp
bolt.
83. Repeat operation for 3rd/4th sclcctor fork and rail.

Gearbox top cover

92. Fit top cover and locate over detent springs.

93. Position breather pipe, locate retaining clips and
secure top cover and breather pipe clips with eight
bolts and spring washers.
94. Fit breather pipe banjo union and fibre washers.
95. Fit reverse light switch.
96. Place clean rag in top cover to prevent entry of dirt
etc.
83
1351 LT85 FIVE SPEED GEARBOX

Bell housing 108. Support underside of gearbox with wooden block.

109. Lubricate oil seal protection sleeve Tool No. LST
97. Remove bolts and spacers securing front bearing 102 and fit to oil seal from inside extension
plate to gearbox. housing.
98. Fit new bell housing gasket. ilG. Fit new gasket to extension housing.
99. Locate bell housing squarely on dowels and 11I . Carefully manoeuvre extension housing over
secure housing and front bearing plate to gearbox mainshaft and position squarely on dowels.
with six bolts and spring washers.

Lower gear leverlbias spring housing

100. Removc rag from gearbox top cover.
101. Lubricate gear lever ball and lower yoke.
102. Fit lower gear lever, nylon cup and grommet.
103. Fit new gasket to housing.
104. Grease bias springs.
105. Carefully fit shims and bias springs, followed by
spring housing and secure with four set screws,
and spring washers.
106. Remove gearbox assembly from vice and detach

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-stand.

Gearbox extension housing

107. The special nut retaining the 5th gcar t o the
layshaft must be secured in position, by carefully
forming the collar of the n u t into the layshaft
slots, as illustrated.

CAUTION: A round nose tool must be used for

this operation to avoid splitting the collar of the 112. Remove oil seal protection sleeve.
nut. Also, the 5th laygear should be supported by a 113. Secure extension housing to gearbox with eight
wooden block when the nut is being deformed, to bolts, spring washers and single n u t .
prevent damage to the bearings adjacent to the
gear. NOTE: Illustration shows correct bolt lengths and
their locations in extension housing.

60"

45" I /n

ST1374M 40"
ST1483M

a4
 LT85 FIVE SPEED GEARBOX 1371
._. .
;.i ... , .,
,;:,’;~
”..::...,,.-
3rd/4th gear selector rail adjustment Bias spring adjustment
.:, -.i
. .I

114. Slacken 3rd/4th stop screw in extension housing. 123. Apply Loctite Stud and Bearing Fit (270) to bias
springs screws and tighten up until screw heads
are flush with top face of bias spring housing.

123 II

115. Select 3rd gear.

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116. Tighten stop screw until it makes contact with
Gearbox mounting
3rd/4th selector rail.
117. Turn back stop Screw one turn. Retighten 124. Refit mounting to extension housing and secure
locknut. with four bolts.
118. Return gear lever to neutral.
119. Slacken locknut on 3rd/4th stop bolt inside bell
housing.

ST1376M ‘\

120. Unscrew stop bolt.

121. Select 4th gear and screw in stop bolt until contact
is made with 3rd/4th selector shaft.
122. Turn back stop bolt one turn and rctighten
locknut.
Return gear lever to neutral.

85
 37 LT230T TRANSFER GEARBOX

REMOVE LT230T TRANSFER GEARBOX

FROM THE LT85 GEARBOX

Special tool: 18G 1425 -Guide studs (3)

Also, locally manufactured adaptor plate, see below

Adaptor plate for removing transfer gearbox

The transfer gearbox should be removed from

underneath the vehicle, using a hydraulic hoist. An
adaptor plate for locating the transfer gearbox onto the
hoist can be manufactured locally to the drawing
below. If a similar adaptor plate was made for the
Lr230R transfer gearbox, it can be modified to suit
both the LT230R and LT230T gearboxes by making the
modifications shown by the large arrows.

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rl
i

ARC WE,LD TO BS5135

I 1 12.63 67.0 12.63 6x0) 1 0.56
6- 5 -4-3
I 5
139.7
- 5 2 -
165.1

;r--...----,
! 6.43 !

Material. Steel plate BS 1449 Grade 4 or 14

Holes marked thus * to be drilled to fit hoist being
used.

$ = MODIFICATION
86
 LT230T TRANSFER GEARBOX I37I
16. Remove three nuts and bolts securing the right-
handgearbox mounting bracket to the chassis, then
1. Install the vehicle on a ramp. remove the n u t from the rubber mounting and
2. Disconnect thc battery. withdraw the bracket.
3. Remove the cover panel from the right-hand seat 17. Place a suitable wooden block between the indin
base. gearbox and chassis cross-member, then lower the
4. Remove the breathcr pipe union from the transfer hoist until the gearbox contacts the wooden block.
gearbox high/low cross-shaft housing. 18. Disconnect the electrical lead from thc differential
5. Disconnect the high/low lever. lock switch.
19. Move the small crank lever, for the highhow
selector, upward to allow access to the adjacent n u t
securing t h e transfer box to t h e main gearbox
extension case.
20. Remove t h e two nuts and four bolts securing the
transfer box to t h e main gearbox extension case.
21. Fit three guide studs, 18G 1425, through the
transfer box bolt holes to support i t during
removal.
22. Lower the hoist and withdraw the transfer box
from the vehicle.

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Refitting

6. Disconnect the transmission brake cable at the 23. Make sure that the joint faces of the transfer box
clevis joint. and main gearbox extension case are clean and that
., .. .. . 7. Raise the vehicle on the ramp and drain the oil the three guide studs, 18G 1425, arc fitted to the
from the transfer box. extension case.
8. Remove the centrc section of the exhaust system. 24. Lubricate t h e oil scal in the joint face of transfer
9. Disconnect the f r o n t and rear propeller shafts from box, secure the transfer box to the adaptor plate on
the gearbox and move them aside. t h e lifting hoist and raise the hoist until the transfer
10. Disconnect the speedometer cable from the box can be located over the guide studs.
transfer gearbox. 25. Remove the guide studs and secure the transfer
11. Remove the split pin at the lower end of the pivot box to the main gearbox extension case. Tighten
arm for the differential lock control. Then, rcmove the nuts and bolts to t h e corrcct torque.
the two bolts securing the pivot arm to allow the 26. Complete t h e refitting procedurc by reversing the
link to be disconnected. removal sequence, noting the iollowing important
12. Manufacture an adaptor plate in accordance with points.
the drawing, to attach to the gearbox hoist and 27. After removing the lifting hoist and adaptor plate
transfer box to facilitate removal (RR244M). from t h e transfer box, clean the threads of the four
13. Place four, 30 mm (1.250 in) long spacers between bolts for the transfer box bottom cover, coat them
the top ef the hoist and the adapter p!ate at the \,xdjth Lectitc 290, 2nd fit them tegethcr with snrinuY "'b
a

securing points and secure the adaptor plate to the washers. Tighten to the correct torque.
hoist. 28. Refill the transfer box with the correct grade oil to
14. Remove the four central bolts from the transfer the oil level plug hole.
..:, '.
, . box bottom cover, move the hoist into position and 29. Check, and if necessary top up, the oil level in the
. .
secure the adaptor plate to the transfer box. main gearbox. Use the correct grade oil.
15. Adjust the hoist to take the weight of the transfer 30. Check the operation of the handbrake and adjust
box. as necessary.
87
 -
37 LT230T TRANSFER BOX

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88
LT230T TRANSFER BOX

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89
 LT230T TRANSFER BOX

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90
 LT230T TRANSFER BOX 37 L

-_
,:”:!:. .
*..., LT230T TRANSFER GEARBOX OVERHAUL
8K.:;y.:.,
,. ._ .;-
....
Service Tools: 1861422 -Mainshaft rear oil seal replacer
18G47-7 - Input gear cluster bearing cones remover/ 1861423 - Adaptor/socket centre differential stake nut
replacer remover/replacer
18G47RB-1 - Adaptor centre differential bearing 18G 1424 -Centre differential bearing replacer
remover MS47 - Handpress
18G47BB-3 - Adaptor centre differential bearing MS550 -Bearing and oii seal replacer handle
remover button LST47-1- Adaptor centre differential bearing remover
18G257 - Circlip pliers LST104 - Intermediate gear dummy shaft
18G1205 - Propflange wrench LST105 -Input gear mandrel
18G1271 -Oil seal remover LST550-4 -Intermediate gear bearing replacer

TRANSFER BOX DATA

Front bevcl gcar end-float . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,075 mm (0.001 to 0.003 in)

Rear bevel gear end-float . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,075 mm (0.001 to 0.003 in)

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Rcar output housing clearance . . . . . . . . . . . . . . . . . . . . . 1,OO mm (0.039 in)
High range gear end-float . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 to 0,15 mm (0.002 to 0.006 in)
Front differential bearing prc-load . . . . . . . . . . . . . . . . . . 1.36 to 4.53 kg (3 to 10 Ibs)
Input gear bearing pre-load . . . . . . . . . . . . . . . . . . . . . . . . 2.26 to 6.80 kg (5 to 15 Ibs)
Intermediate shaft bearing pre-load . . . . . . . . . . . . . . . . . 1.81 to 4.53 kg (4 to 10 Ibs)

Transmission brake removal (if not previously Bottom cover removal

removed)
3 . Rcmove the six bolts and washers retaining thc
1. Remove two countersunk screws and withdraw bottom cover.
brake drum. 4. Remove the gasket and bottom cover.
2. Remove four bolts securing the brake back-plate;
the two bottom fixing retain the oil catcher.
NOTE: An hexagonal type socket should be used for
these bolts.

ST

91
 LT230r TRANSFER BOX

Intermediate shaft and gear cluster removal 10. Remove taper roller bearings and bearing spacer
from the intermediate gear cluster assembly.
5 . Release stake nut from recess in intermediate shaft
and remove stake nut and discard.
6. Unscrew the single bolt and remove anti-rotation
plate at the rear face of the transfer box.

ST1574M 10
Power take-of cover removal

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11. Remove six bolts and washers retaining the take-
off cover and speedo cable clips.
12. Remove the gasket and cover.
7. Tap the intermediate gear shaft from the transfer
box. // f-- ,

Input gear removal

8. Lift out the intermediate gear cluster and bearing
assembly . 13. Remove the two countersunk screws and detach
9. Remove the ‘0’rings from the intermediate gear t h e main shaft bearing housing.
shaft and from inside the transfer box. 14. Remove the gasket.
15. Withdraw t h e input gear assembly.
16. Prise out and discard the oil seal at the front of the
transfer box casing using service tool 1861271.
17. Drift out the input gear front bearing track.

$Ti

92
ST1576M - x .J
 LT230T TRANSFER BOX 1371
Highhow cross-shaft housing removal

18. Remove the six bolts and washers retaining the

cross-shaft housing and earth lead.
19. Remove thc gasket and cross-shaft housing.

Rear output housing removal

23. Remove six bolts and washers and dctach the rear
output housing and shaft assembly from the
transfer casing.
24. Remove the gasket.

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S T I 577M
-

Front output housing removal

20. Remove the eight bolts and washers and detach t h e
output housing from the transfer box casing, taking
care not to mislay the dowel.

Centre differential removal

21. Remove high/low selector shaft dctent plug, spring
and retrieve the ball with a suitable magnet. Transfer case overhaul -dismantling
25. Remove the studs and dowels.
26. Remove the magnetic drain plug and fi!ler!level

22. Withdraw the centre differential and sclcctor shaft/

fork assembly. ST1581M

93
 i
37 I LT230T TRANSFER BOX

27. Drift out differential rear bearing track.

28. Clean all areas of the transfer casing ensuring all
traces of “Loctite” are removed from faces and
threads.

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Transfer case overhaul -re-assembling 3 . Remove speedo-drive housing. This can be prised
out with a screwdriver.
29. Fit studs and dowels to front face of t h e transfer 4. Remove housing from the vice and drift out the
casing . output shaft, by striking the flange cnd of the shaft.
NOTE: The position of the radial dowel blade is set 5 . Carefully prise off thc oil catch ring using a
in line with the circle which is formed by the front screwdriver in the slot provided.
output housing fixing holes.
30. Refit magnetic drain plug with new copper washer
and tighten t o the specified torque, loosely f i t the
filler/level plug.

29

6. Prise out and discard the seal from the output

housing using tool 1SG1271.
7. Using circlip pliers 18G2.57, rcmovc the circlip
retaining the bearing.

Rear output housing overhaul -dismantling

1. Using- flange wrench 1861205 and socket spanner,
remove the flange nut, steel and felt washers.
Ensure flange bolts are fully engaged in the
wrench.
2. Remove output flange with circlips attached. If
necessary, use a two-legged puller.
NOTE: The circlip need only be released if the
flange bolts are to be renewed.
94
 .
,

ST1588M

95
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 37 LT230T TRANSFER BOX

20. Slide drive gear and spacer on to the output shaft. 5. Remove the high range gear and bush, taking care
21. Locate output shaft into the bearing in the housing not to disturb the high/low sleeve.
and drift into position. 6. Mark the relationship of the high/low sleeve to the
22. Locate speedometer gcar (driven) housing hub and then remove the sleeve.
assembly into the output housing and press in until 7. Using a suitable press behind thc low range gear
flush with the housing face. carefully remove the high/low hub and low range
gcar.

-
ST1640M

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Centre differential unit overhaul -dismantling

1. Secure centre diffcrential unit to a vice fitted with

soft jaws, and release stake nut from recess.
2. Remove stake nut using tool 1831423 and suitablc
socket wrench.
3. Removc thc diffcrential unit from the vice.

ST1593M

8. Substituting collar LST47-1 remove front taper

roller bearing.
9. Remove hand press from the vice.
10. Using soft jaws secure the differential unit in the
vice by gripping the hub splines.

4. Secure hand press MS47 in vice with collars

18G47BB and using button 1847BB/3 rcmove the
rear taper bearing and collars.

ST1592M STl596M \ll Y I

96
 LT230T TRANSFER BOX

- _.
........_
... , 11. Remove the eight retaining bolts and lift off t h e 22. Measure t h e front upper bevel gear thrust washer
.: : ..'
,(.,.....
... .. front part of the differential unit. and note the thickness.
12. Release the retaining ring and remove front upper 23. Fit the thrust washer and bevel gear to the front
bevcl gear and thrust washer. unit.
13. Rcmove the pinion gears and dished washers along 24. Refit the retaining ring and front differential unit,
with the cross shafts. aligning the two engraved arrows marked on both
14. Remove the rear lower bevel gear and thrust halves of the unit.
asher from the rear part of the differential unit. 25. Fit four bolts equi-spaced and torque to the correct
figure.

114
25-

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26. Mcasure the front bevel gear end-float with fcclcr
gaugcs through the slots provided in the front
differential unit. The end-float must be 0,025 to
0,075 mm (0.001 to 0.003 in) maximum. When
measuring use two sets of feelcr gauges, one on
ST 1 each side of the front differential unit. This will
give a true reading of the end-float.
15. Remove thc rear differential unit from thc vicc and
clean all components; examine Tor wcar or clamage
and renew if necessary.
16. Clean all components; examine for wear or damage
and renew if necessary.
17. Using soft jaws secure the rear differential unit in
the vice by gripping the hub splincs.
IS. Ensure that all differential components arc dry to
assist in checking end-float.
19. Using a micrometer, measure one of the bevel gear
thrust washers and note the thickness.
20. Fit the thrust washer and bevel gear to the rear
lower differential unit.
21. Assemble both pinion asscmblies and dished
washers on to their respective shafts and fit to the
rear differential unit.
97
137 I LT230T TRANSFER BOX

27. Invert the differential unit and repeat operation 26

for the rear bevel gear end-float.
28. Invert the differential unit and secure in vice and
remove the four bolts and lift off the front
differential unit.
29. Remove the rctaining ring, bevel gear and the
washer and both pinion assemblies.
30. Select the correct thrust washers required for final
assembly.

Reassembling
31. Fit the selected thrust washer and bevel gear into
the rear lower differential unit.
32. Assemble both pinion assemblies and dished
washers on to their respective shafts and fit the rear
differential unit. Secure t h e assemblies with the
retaining ring.
33. Lubricate all the components.
34. Fit the selected thrust washer and bevel gear into

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the front upper differential unit.
S7'1 602

38. Fit the low range gear, with its dog teeth upper-
most to the differential assembly.
39. Prcss the highllow hub on to the differential
spli nes.
40. Slide the high/low selector sleeve on to the high/
low hub ensuring that t h e alignment marks are
opposite each other.
41. Fit the bush into the high range gear so that the
flange is fitted o n the opposite side o f the gear to
thc dog teeth. Slide the bushed gear on to the
differential assembly with the dog teeth down.

41

ST
39
35. Align both units as previously described and secure
with the eight bolts to the specified torque.
36. Finally check that the differential gears rotate
freely. Locate the front differential bearing onto
the front, upper differential shaft and press into
position using larger end of tool 1861424 as shown.
37. Invert the differential unit and secure in the vice.
NOTE: During the following sequences all parts
should be lubricated as they are fitted. ST1599M
98
 LT230T TRANSFER BOX

.--
. .....:
,,,:~,:~~. 42. Locate the rear differential bearing on to the hub 48. Fit the new selector fork with its boss towards the
..
...i .~
!.,E
.". > .I and press it into position using the smaller end of three detent grooves. Align the tapped hole in the
tool 18G1424. fork boss with the indent in the shaft nearest to the
43. Fit the stake n u t and tighten to the specified torque detent grooves.
using tool 18G1423. 49. Apply Loctite 290 to the set screw threads and fit
44. Check the cnd float of the high and low rangc gears the set screw and tighten to the specified torque.
0,05 to 0,15 nim (0.002 to 0.005 in).
NOTE: If the clearances vary from those specified
in the data, the assembly must be rebuilt using the
relevant new parts.

1 . .
.. ,

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ST1605M

ST1603M

Centre differential rear bearing track

45. Peen the stakc n u t collar by carefully forming the
collar of the n u t into thc slot a s illustrated. 50. Fit the differential rear bearing track 1,OO mm
CAUTION: A round nose tool must be used for this (0.039 in) below t h e outer facc of casing using a
operation to avoid splitting the collar of the nut. suitablc tool as shown.

~ ~~ ~

1 .OO mm (0.039in)
1

50

ST1606M 1
ST1604M

46. Clean and check high/low selector fork assembly Rear output housing -refit
.... .....,..
. I
for wear and renew i f necessary.
47. To renew the selector fork remove the square set I . Grease output housing gasket and position on to
screw and slide thc fork from the shaft. the rear facc of thc transfer box casing.
99
 37 LT230T TRANSFER BOX

2. Fit output housing and ensure clearance of 4. Apply Loctite 290 to decent plug; fit and locate, by
1.00 mm (0.039 in) between housing face and screwing gently fully home and then unscrewing
gasket. two turns.
3. Fit the six output housing bolts with Loctite 290 on
t h e threads, with washcrs and tighten evenly to the
correct torque, which will pull the rcar bcaring into
position.

Front output housing overhaul -dismantling

1. Unscrew seven retaining bolts and washcrs and
remove the differential lock sclector side cover and :z->:
--

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E
gasket.
2. Unscrew thrce retaining bolts and washers and lift
the differential lock finger housing and actuator
assembly from the front output housing.
3. Slackcn the locknut and unscrew the differential
ST1594M
- lock warning light switch.
Centre differential unit refit 4. Rcmovc selector shaft dctent plug, spring and ball
using a suitable magnct.
1. Fit the sclcctor forkhhaft assembly to the high/low
selector slecvc on the differential assembly, with
detent groove to the rear of the differential
asscm bly .
2. Locatc the differential assembly complelc with
selector fork into t h e transfer box casing. I t may be
necessary t o rotate the output shaft to ease fitment,
and engage selector shaft into its hole.

5 . Compress the selector fork spring and remove the

two spring retaining caps.

ST1607M M
3. Fit selector shaft ball and spring through the side of
the transfer box casing.
100
 LT230T TRANSFER BOX 137 I

4.:
c\j
dL
6. Withdraw the selector shaft from the rear of the
output housing.
7. Remove the selector fork and spring through the
side cover aperture.
8 Remove lock-up sleeve from the rear of the output
housing.

15. Invert housing and drift out bearing from inside the
case as shown.

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9. Using flange wrench 18G1205 and socket wrench,
remove the flange n u t , steel and felt washers.
NOTE: Ensure that flange bolts are fully engaged in
the wrench
10. Remove the output flange with oil seal shield.
NOTE: These parts need not be separated unless the
flange bolts are to be renewed.
11. Drift output shaft rearwards from housing using a 16. Drift out centre differential front taper roller
soft headed mallet. bcaring track and shim.
12. Slide off the collar from the output shaft 17. Drift out selector shaft cup plug from housing.
;., .,
I 18. Clean all components ensuring all traces of
A ”

“Loctite” are removcd from faccs and threads.

10 19. Examine components for wear or damage and
renew if necessary.
NOTE: Renew oil seal and felt seal and flange nut.

. .4.,:.,.;
..
.:.:. .. ~

13. Prise out and discard oil seal from output housing
using service tool 1861271.
14. Remove circlip with circlip pliers 186257.
101
 LT230T TRANSFER BOX

Keassembling 29. Grease and fit new gasket and locate the front
output housing on the transfer box casing.
20. Press the bearing into the housing; do not use 30. Secure housing with the eight retaining bolts and
excessive force. To facilitate fitting the bearing, washers, the upper middle bolt being longer than
hcat the front output housing. (This is not to the rest. Do not tighten the bolts at this stage.
exceed 1OOOC). 31. Engage high or low gear.
21. Using circlip pliers 186257, fit the bearing 32. Check t h e rolling resistance of the differential
retaining clips. using a spring balance and a length of string wound
22. Fit a new oil seal (open side inwards) using replacer around the exposed splines of the high/low hub.
tool 18G1422, until the seal just makes contact with 33. With the correct shim fitted the load to turn should
the circlip. be 1.36 kg to 4.53 kg (3 Ibs to 10 Ibs). This applies
23. Carefully charge the lips of the seal with clean to new or used bearings. (New bearings will
grease. register at the top end and used bearings will
24. Slide collar on to the output shaft, with its register at the low end.
chamfered edge towards the dog teeth. 34. If the reading is in excess of the above
25. Fit the output shaft through the bearing and drift measurements, remove the front output housing
home. assembly from the transfcr box casing.
35. Using a suitable cxtractor, withdraw the centre
differential bearing track and change the shim for
one of a suitable thickness. ( A thinner shim will ~5'3

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. ...'
I'L
reduce the rolling resistance). C'-

36. Fit the new shim and drift t h c differential bcaring

track back into its housing until fully home.
37. Having obtained the load to turn, prop-up the
transfcr box casing on the bench with the front face
uppermost.

ST1614M
Adjusting front differential bearing pre-load
26. Measure original differential front bearing track
shim.
27. Refit original shim into input housing.
28. Drift differential f r o n t bearing track into thc
housing.

ST1616M

38. Apply Loctite 290 to the threads of the housing

rctaining bolts and fit the eight bolts and washers
into the front output housing and secure to transfer
box casing.
39. Fit front output flangc, felt washers, steel washers
and flange nu!.
40. Using flange wrench 1861205 and torque wrench
pull the output shaft up to the correct position.
Check that the oil seal shield does not foul the
housing. &:; i'-..
...i
et:;/'
NOTE: Ensure that the flange bolts are fully
engaged in the wrench.
102
 LT230T TRANSFER BOX 5
1
46. Compress the spring between the fork lugs and
slide the retaining caps o n to the shaft ensuring the
spring is captured with the “cupped” side of the
caps.
47. Drift selector shaft sea! cup into position.

41. Repeat the above operation for the rear output

flange.

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48. Fit selector shaft dctcnt ball and spring in the
tapped hole on top of the output housing.
40. Apply Loctite 290 to detent plug threads. Screw
detent plug gently homc and then unscrew two
turns.

42. Compress the selector shaft spring and fit to the

selector fork.
:i, ;:. 43. Locate selector fork through front output housing
, .I

side cover aperture, ensuring that the fork engages

in the groove of the lock-up sleevc.
44. Fit selector shaft through the aperture in the front
of the output housing and pass i t through t h e
sclector fork lugs and spring into the rear part c.f
the housing.
45. Rotate the selector shaft until the two flats for the STI 645M
spring retaining caps are at right angles to the side Differential lock finger housing overhaul -dismantling
cover plate face.
1. Unscrew and discard t h e “nyloc” nut and remove
the operating lever and washer.
2. Remove t h e pivot shaft from lock finger housing.
3. Remove the ‘0’ rings from the pivot shaft and
housing and discard.
4. Clean all components; examine for wear or damage
and renew if necessary.

Reassembling
5 . Fit new ‘0’ rings on to pivot shalt and lock finger
housing and lubricate with oil.
6. Locate the pivot shaft in t h e housing.
103
 37 I LT230T TRANSFER BOX

7. Fit the differential lock lever over the pivot shaft so High/low cross-shaft housing overhaul
that the lever will face forward with the bcnd
upwards. This lever is then in the correct operating 1. Remove t h e selector finger grub screw and
position. withdraw the cross-shaft from the cross-shaft
S. Retain the lever with a plain washer and new nyloc housing and remove the selcctor finger,
nut. 2. Remove the ‘0’ring from the cross-shaft.
3. Drift out selector housing cup plug if necessary.
4. Clean all the components and chcck for damage or
wear, replace if necessary.
5 . Apply sealant to a new cup plug and fit so that the
cup is just below the chamfcr for the cross-shaft
bore.
6. Fit new ‘0’ring to cross-shaft.
7. Lubricate the shaft and insert into the cross-shaft
housing.
8. Fit selector finger ensuring that it aligns with the
recess in the cross-shaft.
9. Apply Loctite 290 to the grub screw and secure the
selector finger to the cross-shaft and fully tighten to
thc specified torque.

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ST1618M

9. Fit the differential lock finger housing into its

seating On the front output housing, ensuring (hat 10. Grease and fit the high/low selector housing gasket
the selector finger is located in the flat of the on the front output housing.
11. Fit high/low cross-shaft housing, ensuring that the
selector shaft.
10. Apply Loctitc 290 to thc bolt threads and retain thc
lock finger housing with the three bolts and
selector finger locates in the slot of the selector
shaft, and secure with six bolts and washers to the
r;
-es!
washers to the specified torque. specified torque.
n/

ST1646M

Input gear overhaul -dismantling

ST1619M
1. Clean the input gear assembly and examine for
wear or damage. Remove the bearings only if they
are to be renewed.
104
 LT230T TRANSFER BOX 37
L

<..,. .. ...
...... ....
..,:
..,... .,.. 2. Secure hand press MS47 in the vice and using
:,,.
-" I
collars 18G47-7 and button l8G47-BB/3, remove
rear taper roller bearing from input gear assembly.
3. Invert input gear assembly in hand press and
remove front taper roller bearing.
4. Clean input gear.

1 .

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..,

9. Reposition transfer box casing so the front face is

uppcrmost and fit oil seal (open sidc inwards) using
replacer tool 18G1422.
Reassembling
5 . Position rcar taper roller bcaring on input gear and
using hand press MS47 and collars 18647-7 press
the bearing fully homc.
6. Invert input gcar and fit the front taper roller
bearing using t h e press and collars.

7. Prop up the transfer box casing on the bench with 10. Lubricate both bearings with clean oil.
the rear face uppermost. 11. Fit the input gear assembly into the transfer box
8. Drift in the front taper bearing track. casing with the dog teeth uppermost.
105
 El LT230T TRANSFER BOX

Checking input gear bearing pre-load 22. Remove the spring balance, string and service tool.
23. Remove the six bolts and the bearing support
12. Secure bearing support plate in the vice. Drift out plate.
input gear bcaring track, and remove shim. 24. Drift out the input gear bearing track from the
13. Clean hearing support plate and shim. Measure support plate and discard original shim.
original shim and note its thickness. 25. Select t h e correct size shim to obtain a load to turn
14. Fit the original shim to the support plate. of 2.26 kg to 6.80 kg (5 Ib to 15 Ibs).
15. Locate the bearing track in the support platc and 26. Fit shim to support plate, locate bearing track and
press fully home. press home.
27. Fit bearing support platc and secure to transfer box
casing with the six bolts (do not tighten).
28. Repeat the rolling resistance check as previously
described, and note the value obtained.

Intermediate gear assembly overhaul

1. Drift out intermediate gear bearing tracks
2 . Remove circlips.

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16. Apply grease to the gasket and fit on to the transfer
box casing.
17. Fit the bearing support platc on to the transfer box
casing and secure with the six bolts, but do not
ST1628M
tightcn.
18. Fit the servicc tool LST105 to input gear and 3. Clean all intermcdiate gcar components and lock
engage the spline. plate. Check for damage o r wear and replace as
19. Tie a length of string to the split pin and f i t i t to the necessary .
service tool as shown. 4. Fit new circlips into the intermediatc gcar cluster.
20. Attach a spring balance to the string and carefully 5. Using tools LST5.50-4 and MS550 fit bcaring tracks
tension the spring until a load to turn t h e input gear
is obtained. A pull of 2.26 kg to 6.80 kg (5 Ib to
15 Ibs) is required.
21. If the reading obtained is outside t h e above limits,
the original shim must be changed.

106
 TRANSFER BOX
L~230T 137 I
..... .
,L;!-:
./
6. Fit the '0' rings to the intermediate shaft and into 13. Turn the intermediate shaft to allow fitting of
the intermediate shaft bore at the front of the retaining plate.
transfcr box casing. 14. Fit retaining plate and secure with retaining bolt
and washer.
15. Fit thc intcrmediate gear shaft retaining stake nut.

Intermediate gear reassembly

7. Check for damage to the intermcdiate shaft thread
and if neccssary clean up with a fine file or stone.
- .. ..-
,. .'. ....,
'.,..
8. Lubricate the taper roller bearings and
intermcdiate gear shaft.

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.
I

, z..
. ...
..
...:, . I

9. Insert new bearing spacer to gear assembly,

followed by the taper roller bearings. Adjusting intermediate gear torque-to-turn
16. Select neutral.
17. Fit service tool LSTlO5 to input gear and cngagc
spline.
18. Tic a length of string to a split pin and fit to the
service tool as shown. Attach thc spring balance to
the string.
19. To obtain the correct figures and to collapsc thc
spacer within the intermediate gear cluster, tighten
the intermediate shaft nut until the load-to-turn has
increased by 3.7 kg (7 Ibs) 5 1.63 kg (F 3 Ibs) on
that noted when checking input shaft load-to-turn.
The torque to tighten the retaining nut will be
ST1649M approximately 203 Nm (150 Ib ft).
10. Fit dummyshaft LST104 into the intermediate gear 20. Peen the stake n u t by carefully forming the collar
cluster. of the nut into the intermediate shaft recess, as
.,.,,..
:... illustrated.
.
1 ..;.:I
.,. 11. Locate the gear assembly into the transfer box
.,, .
casing from the bottom cover aperture. CAUTION: A round nose tool must be used for this
12. Insert intermediate shaft from the front of the operation to avoid the collar of the nut.
transfer box casing, pushing the dummy shaft right
through as shown and remove. (Making sure that
the intermediate gear cluster meshcs with the input

<:: :
'..,...
'I: ,:.. i,
.

107
 LT230T TRANSFER BOX

Power take-off cover -reassemble

21. Clean power take-off cover and gasket facc.
22. Fit the two countersunk screws and tighten. + -
23. Remove ihe six bolis from the bearing support
plate. 3-
24. Apply sealant to the cover plate gasket and fit it to
the bearing support plate.
25. Apply Loctitc 290 to bolt threads and secure the
power take-off cover with the six bolts and
washers.

Bottom cover -reassemble

26. Clean bottom cover and gasket face.

27. Apply sealant to cover gasket and fit to transfer
box casing.
28. Apply Loctite 290 to bolt threads and secure the
bottom cover with six bolts and washers.

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STl634M
-
6. Disconnect the battery and m o v c the dirfercntial
lock lever to t h e left to disengage differential lock.
7. Clean thc front output housing side cover.
8. Grcase and fit side cover gaskct.
9. Apply Loctite 290 to bolt threads, fit side cover and
secure with sevcn bolts and washers.

Transmission brake - reassemble

NOTE: Under certain circumstances it is better to fit the
transmission brake assembly after being installed in the
vehicle.
Differential lock switch adjustment 1. Clcan brake backplate and oil catcher and apply
sealant to the catcher joint face.
1. Select differential locked position by moving the 2. Locate brake backplate on the rcar output housing
lock taper towards the right side of the transfer box with the brake operating lcver o n thc right side of
casing. the transfer box casing.
2. Apply sealant to the diffcrential lock warning light 3. Secure the backplatc (including the oil catcher)
switch and fit to the top of the front output with the four special bolts and tighten using 21
housing. hexagonal socket to the specified torque.
3. Connect a test lamp circuit to the differential lock 4. Clean and fit brake drum and secure with two
switch. countersunk screws.
4. Screw in the lock switch until the bulb is
illuminated.
5. Turn in the switch another half a turn and tighten
with the locknut against t h e housing.
 PROPELLER SHAFTS 147 I
,. .;” OVERHAUL PROPELLER SHAFTS 6. Remove paint, rust, etc. from the vicinity of the
.. universal joint bearing cups and circlips.
Dismantle

1. Remove the propeller shaft from the vehicle

2. If a gaiter encloses the sliding member release the NOTE: Before dismantling the propeller shaft joint,
two securing clips. Slide t h e gaiter along the shaft
mark the position of the spider pin lubricator relative to
to expose the sliding member.
the journal yoke ears to ensure that the grease nipple
3. Note the alignment markings on the sliding
boss is re-assembled in the correct running position to
member and the propeller shaft. Sec note following
reduce the possibility of imbatance.
instruction 22.
7. Remove the circlips, and grease nipple.
3

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STlOOOM

4. Unscrew the dust cap and withdraw the sliding

member.

STl 00 3 M

8. Tap the yokes to eject the bearing cups.

9. Withdraw the bearing cups and spider and discard.
10. Repeat instructions 5 to 8 at opposite end of
propeller shaft.
11. Thoroughly clean the yokcs and bearing cup
locations.

STlOOlM

5 . Clean and cxamine the splines for wear. Worn

splines or excessive back-lash will necessitate
propcller shaft renewal.

ST1004M

ST1002 M
 47 PROPELLER SHAFTS

Assemble 22. Lubricate the sliding member spines and fit the
sliding member to the propeller shaft ensuring that
12. Remove the bearing cups from the new spider. the markings on both the sliding member and
13. Check that all needle rollers are present and are propeller shaft align.
properly positioned in the bearing cups.
14. Ensure bearing cups are one third full of fresh NOTE. The Universal joints on the front propeller
lubricant. See Lubrication chart. shaft are, by design, not assembled in-line with one
15. Enter the new spider complete with seals into the another. Nevertheless, the alignment marks on the
yokes of the sliding member flange. Ensure that sliding member and propeller shaft must coincide
the grease nipple hole faces away from the flange. when assembling.
16. Partially insert one bearing cup into a flange yoke
and enter the spider trunnion into the bearing cup 23. Fit and tighten the dust cap.
taking care not to dislodge the needle rollers. 24. Fit the grease nipples to the spider and the sliding
17. Insert the opposite bearing cup into the flange member and lubricate.
yoke. Using a vice, carefully press both cups into 25. Slide the gaiter (if fitted) over the sliding member.
place taking care to engage the spider trunnion 26. Locate the sliding member in the mid-position of
without dislodging the needle rollers. its travel and secure the gaiter clips. Note that the
18. Remove the flange and spider from the vice. gaiter clips must be positioned at 180" to each other
19. Using a flat faced adaptor of slightly smaller so that they will not influence propeller shaft
- diameter than the bearing cups press each cup into balance.

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its respective yoke until they reach the lower land
of the circlip grooves. Do not press the bearing
cups below this point or damage may be caused to
the cups and seals. 26

ST 1007M

27. Apply instructions 15 to 20 to the opposite end of

the propeller shaft.
rJ
I - 28. Fit the grease nipple and lubricate.
ST1005 M 29. Fit the propeller shaft to the vehicle.

20. Fit the circlips.

21. Engage the spider in the yokes of the sliding
member. Fit the bearing cups and circlips as
described in instructions 15 to 20.

ST1006M

2
 REAR DIFFERENTIAL -NINETY HEAVY DUTY
- ~~

. .,
OVERHAUL REAR AXLE DIFFERENTIAL 7. Remove the split pin securing the pinion flange
ASSEMBLY - Land Rover Ninety Heavy Duty
I1
ye, nut.
(option) 8. Remove the pinion flange n u t using service tool
18G 1205, to rcstrain the flange.
Service tools:
18G 1205 flange holder tool;
18G 191 pinion height setting gauge;
18G 191-4 universal setting block;
18G 47-6 pinion head bearing removerlreplacer;
18G 1382 oil seal replacer;
RO 262757A extractor for pinion bearing caps;
RO 262757-1 replacer - use with RO 262757A;
RO 262757-2 adaptor tail bearing cap replacer;
RO 530105 spanner - differential flange and carrier
bearing nuts;
RO 530106 bracket for dial gauge and indicator;
MS 47 press

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9. Withdraw the pinion complete with pinion head
bearing and outer bearing shims. Withdraw the
shims.
DISMANTLE 10. Remove the pinion flange oil seal, spacer and
bcaring. Discard the oil seal.
It is essential that differential components are marked
in their original positions and relative to other
components so that, if refitted, their initial setting is
maintained. Note that the bearing caps must not be
interchanged. 9

1. Remove the differential assembly from the axle.

2. Drift out the roll pin securing the bearing nut
locking fingers to the bearing caps. Remove the
locking fingers.
3. Slacken the bcaring cap bolts and mark the caps for
reassembly.
4. Using service tool R O 530105, remove the bearing
ST506M
adjusting nuts.
5. Remove the bearing cap bolts and bearing caps.
6. Lift out the crown wheel, differential unit and
bearings. 11. Using service tool R O 262757A rcmove the pinion
head bearing track and shim and drift out the outer
bearing track from the differential housing.
continucd

1
151I RE A R DIFFERENTIAL -NINETY HEAVY DUTY

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ST508M ST1202M \
18. Dismantle the pinions and crosspin assembly,
12. Remove the pinion head bearing with service tool
noting the relevant positions of all components.
MS 47 and adaptor 18G 47-6.
19. If required, extract the rollcl- bearings and place
13. For rcasscmbly purposes, add alignment marks to
them in thcir relative outer tracks.
the crown wheel and differcntial case halves.

WARNING: To avoid personal injury, the differential

INSPECTING
assembly must be very securely retained while removing 30. ~~~~i~~ components for obvious wear or
the bolts from the crown wheel and case halves, as these damage.
bolts are Loctited and may be difficult to remove. 21. A11 bearings must be press fit, except the flange
end pinion bearing, which must be a slide fit on the
A retaining fixture can be made from angle iron with a shaft.
tube and two bolts welded to it, as illustrated, so that 22. The crown wheel and pinion are only supplied as a
when the fixturc is clamped in a vice, the differential matched set and must not be interchanged
assembly can be located over the tubc with the fixture separately.
bolts between the case webs. 23. Bevel pinion housing and bearing caps are matched
sets and must not be interchanged separately.
14. Remove the crown wheel. 24. The differcntial case halves are a matched set and p:>.
15. Remove thc screws holding t h e case halves must not be interchanged separately. New screws %.*.
together. for securing the case halves are already coated with
16. Withdraw the upper half of the casing. a dry locking compound and do not require the
17. Withdraw the upper side gear. Note that there may application of Loctite. If t h e old screws are being
be thrust washers fitted to the side gears. reused, t h c threads must bc cleaned and coated
with Loctite ‘Studlock’ just prior to assembly.

2
ST889M
 RE A R DIFFERENTIAL - NINETYHEAVY DUTY 51.
~ 2 , - ~ ;ASSEMBLY
.I ,>
40. Remove the crown wheel bolts and refit them using
1- %.A
NOTE: If thrust washers were removed from the side Loctite ‘Studlock’. Evenly tighten the bolts to 5,5
gears during dismantling, the washers must be to 6,3 kgf m (40 to 45 Ibf ft).
lubricated with EP90 oil and refitted during the
following procedure. DO NOT allow oil to contact any
holes or bolts that are to be Loctited.

25. Position the smaller case half with the open side
uppermost and fit the side gear into the case.
26. Assemble the crosspins, pinions and thrust
washers, lubricate the thrust washers with EP90
oil.
27. Fit the crosspin assembly on to the side gear
already contained in the differential case half,
ensuring that the gears locate correctly.
28. Fit the other side gear to the crosspin assembly
ensuring that all the gears locate correctly.
29. Fit the two case halves together, maintaining the
alignment marking and ensuring correct gear
mating.
. 30. Fit the correct (high grade) screws and tightcn

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them evenly to a torque of 3,0 to 3,7 kgf m (22 to
27 Ibf ftj (30 to 36 Nm). ST891M 0
31. Check that the serial number marked on thc pinion
end face matches that marked on the crown wheel. Drive pinion
32. Ensure that the differential housing flange and
crown wheel are thoroughly clean. Align the crown 41. Fit the pinion head bearing track and the original
wheel with the diffcrcntial case, fit the bolts and shim to the pinion housing using service tools
washers and tighten evenly. R O 262757A and R O 262757-1. I f the original
33. If removed, press on the differential roller shim was damaged or mislaid use a new shim of at
bearings. least 1,27 mm (0.050 in) thickness.
34. Place the differential housing complete with crown 42. Fit t h e pinion outer bearing track to the pinion
wheel and bearings in the pinion housing. housing with service tool R O 262757A and
35. Fit the bearing caps and bolts. Do not fully tighten
the bolts. R O 262757-2.
36. Fit the bearing adjusting nuts and adjust to obtain
zero end-float. NOTE: Instructions 41 and 42 are carried out in one
37. Tighten the bearing cap bolts. operation as illustrated.
38. Using a dial gauge check the crown wheel for
run-out. This should not exceed 0,10 mm 43. Fit the pinion head bearing to the pinion using
(0.004 in). If excessive run-out is recorded remove service tool 18G 47-6.
the crown wheel and examine crown wheel and continued
mounting flange for burrs, grit, etc. Refit the
crown wheel and recheck. Run-out, attributable to
a buckled or damaged differential housing flange
can be corrected only by renewing the differential
gear housing.
39. When satisfied that run-out is within t h e specified
limits remove the differential housing from the
pinion housing.

. .,.,...
~
.. .,..
... .I.

.. I

3
 REAR DIFFERENTIAL -NINETY HEAVY DUTY

44. Enter the pinion in its location in the pinion 51. The nominal setting dimension is represented by
housing. Do not fit the shims for bearing pre-load the setting gauge block 18G 191-4 which is
at this stage. referenced from the pinion end face to the bottom
45. Fit the outer bearing and spacer. radius of the differential bearing bore.
46. Fit the driving flange, washer and nut.
Drive pinion adjustment

52. Ensure that the pinion end face is free of raised

burrs around the etched markings.
53. Remove the keep disc from the magnetised base of
dial gauge tool 18G 191.
54. Place the dial gauge and setting block on a flat
surface and zero the dial gauge stylus on the setting
block.

NOTE: 'The setting block has three setting heights

as follows:
39.50 mm Rationalised axle
38.10 mm Pre-Rationalised axle
30.93 mm Salisbury axle <.
--
-.
-A-
.

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Ensure that the height marked 39.50 mm is used $,
for this differential.

47. Do not fit the oil seal at this stage.

48. Tighten the pinion flange n u t slowly until the force
required to rotate the pinion is 23 to 40,5 kgf cm
(20 to 35 Ibf in). This will pre-load the bearings in
order to check the pinion height dimension.
NOTE: If using original bearings, which are bedded
in, the pre-load figure is 11,5 to 17,25 kgf cm (10 to
15 in Ib).
Drive pinion markings
49. The markings on the end face adjacent to the serial
number are of no significance during servicing. g--
T. ,
50. The figure marked on the end face opposite to the
serial number indicates, in thousandths of an inch,
the deviation from nominal required to correctly
set the pinion. A pinion marked plus (+) must be 55. Position the dial gauge centrally o n the pinion end
set below nominal, a minus (-) pinion must be set face with the stylus rcgistering on the loweqt point
above nominal. An unmarked pinion must be sct at on one differential bearing bore. Note the dial
nominal. gauge deviation from the 7eroed setting.
continued

ST894M I I
4
 REAR DIFFERENTIAL -NINETY HEAVY DUTY 151 I
;::-,:;: 56. Repeat on the other bearing bore. Add together 65. With t h e pinion flange nut tightened to a torque of
-. . ... ..
.:c':.
.....
:.
the readings then halve the sum to obtain the mean 9,6 to 16,5 kgf m (70 to 120 Ibf ft) (95 to 163 Nm)
reading. Note whether the stylus has moved up or the force required to rotate the pinion shaft should
down from the zeroed setting. be within 23 to 40,25 kgf cm (20 to 35 lbf ins) when
a.Where the stylus has moved down, the amount is initial inertia has been overcome. Change the
equivalent to t h e thickness of shims that must be bearing pre-load shim as necessary to obtain this
requirement. A thicker shim will reduce pre-load;
removed from under the pinion inner track to bring a thinner shim will increase pre-load.
the pinion down to the nominal position.
b.Where the stylus has moved up, the amount is NOTE: If using original bearings, which are bedded in,
the pre-load figure is 11,s to 17,s kgf,cm (10 to
equivalent to the additional thickness of shims
15 in Ib).
required to bring the pinion up to the nominal
position. 66. Remove the pinion flange.
57. Before adjusting the shim thickness, check the 67. Fit the oil seal (seal lips towards t h e pinion), using
pinion face marking and if it has a plus (+) figure, service tool 18G 1382 oil seal replacer.
subtract that amount in thousandths of an inch
from the shim thickness fieure" obtained in the
previous item.
58. Alternatively, if the pinion has a minus (-) figure,
- ...
..
add the amount t o the shim thickness figure.
,Adjust the shim thickness under the pinion head

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~

. .
bearing track as necessary.
59. Recheck the pinion height setting. If the setting is
correct, the mean reading on the dial gauge will
agree with the figure marked on the pinion end
face. For example, with an end face marking of +3,
the dial gauge reading should indicate that the
pinion is +0.003 ins.

Bearing pre-load adjustment ST897M

60. Remove the pinion flange, pinion, outer bearing
and spacer.
61. Slide new shims, of the same thickness as the
originals (bearing pre-load) into position on the 68. Lubricate the seal lips with EP90 oil. Fit the
pinion shaft. If the original shim was damaged or distance piece and flange and secure with washer
mislaid use a new shim of at least 4,06 mm and nut. Tighten t h c nut to 9,6 to 16,5 kgf m (70 to
(0.160 in) thickness. 120 Ibf ft) (95 to 163 Nm). Fit a new split pin.
continucd
62. Enter t h e pinion i n its location in the pinion
housing and fit t h e outer bearing and spacer.
, .. ,. .
'( . .. 63. Fit the driving flange, washer and nut.
64. Do not fit the oil seal at this stage.

ST898M

:. , 1. ST120lh 7
. .

5
 El REAR DIFFERENTIAL -NINETY HEAVY DUTY

69. Place the differential housing in the pinion

housing.
70. Fit the bearing caps and bolts. Do not fully tighten
the bolts.
71. Fit the bearing adjusting nuts.

76. Evenly tighten the bearing cap bolts torque

* 8,3 kgf m (60 Ibf ft) (82 Nm).

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77. Recheck crown wheel/pinion backlash.
78. Lubricate the bearings and gears.
72 Using service tool R0530105, slackcn the left hand
bearing adjustment n u t (as illustrated) to produce
end float.

I
STQOOM

73. Tighten thc right hand n u t until crown wheel/

pinion backlash is just removed.
74. Tighten the left hand nut slowly until the crown
wheel/pinion backlash is 0.10 to 0117 mm (0.004 to
0.007 in).
75. Fit the locking fingers and roll pins. If nccessary,
tighten the adjustment nuts slightly to align the
locking finger with a slot.

DATA

Pinion bearing pre-load ........................................ 23 to 40,25 kgf cm (20 to 35 Ibf in)

Crown wheel run-out ........................................... 0,10 mm (0.004 in)
Crown wheel/pinion backlash ................................ 0,10 to 0,17 m m (0.004 to 0.007 in)

6
 REAR DIFFERENTIAL - ONE TEN 1
5
1
...
. ...
,..,....
......
.,., OVERHAUL REAR AXLE DIFFERENTIAL 8. Remove the fixings and withdraw the differential
..,
.......,._,.. ASSEMBLY (SALISBURY) LAND ROVER ONE TEN
..,,A
bearing caps.
MODELS
Service tools:
47 screw press;
18G 131 C axle spreader or axle compressor GKN 131;
1SG 191 dial gauge, bracket and base;
18G 1122 screw press;
18G 1205 spanner for drive coupling;
S 123 A pinion bearing cup remover;
18G 47 BK pinion bearing cone removerheplacer;
18G 47 BL differential bearing remover;
18G 1122 G pinion bearing cup replacer;
1% 134 DP differential bearing replacer;
18G I91 P setting gauge for pinion height or I8G 191-4
universal setting block;
18C 131 F pegs for axle spreader;
ST639M
RO 1008 oil seal replacer
- ,
Using axle spreader 18G 131 C

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DISMANTLE
9. Clean out and examine the spreader tool pegholes
NOTE: All fixing bolts used on the differential assembly I

provided in the gear casing face; ensure that the

and differential cover have metric threads.
holes are free from dirt and burrs and damage.
10. Ensure that the turnbuckle adjuster is free to
1. Drain off thc differential lubricating oil, and refit
turn.
PI ug. 11. Fit the axle spreadcr to engage the peg holes.
2. Remove the rear axle assembly from the vehicle.
Spreader 18G 131 C, Adaptor pegs 1% 131 F.
3 . Remove the hub driving mcmbcr fixings.
12. Using a spanner, turn t h e adjustcr until all free
4. Withdraw the driving membcr and axle shaft
play between the spreader and casing is takcn up,
sufficiently to disengage the differential.
denoted by the adjuster becoming stiff to t u r n .
5 . Repeat instruction 4 for the other axle shaft.
13. Check that the side members of the spreader are
6. Remove the fixings and support strip at the
clear of the casing.
differential cover and withdraw the cover and
14. Stretch the casing, rotating the adjuster by one
joint washcr.
flat at a time, until the differential assembly can
7. Note the relationship marking on the bearing caps
be levered out. Do not lever against the spreadcr;
and axle casing to ensure correct refitting.
use suitablc packing under the levers to avoid
damage to the c a m g .
CAUTION: To prevent permanent damage to the
gear carrier case, it must not be over-stretched.
Each flat on the turnbuckle is numbered to enable
a check to be made on the amount turned. The
maximum stretch permitted is 0,30 mm (0.012 in),
equivalent to three tlats.

6 15. Ease off the adjuster and remove t h e spreader

ST650M

7
 REAR DIFFERENTIAL - ONE TEN

Using axle compressor GKN 131

16. Place the tool on to the differential casing, as
21. Note the alignment markings on the two
differential casings to ensure correct refitting,
e
then remove the fixings.
illustrated, with the weld seam uppermost. 22. Lift off the upper case.
Ensure that the plates rest squarely on the 23. Withdraw the upper differentiai wheei and thrust
differential machined surface and the end bars washer.
butt against the edges of the casing.
17. Tighten the adjusting nuts by hand only, until all
slack is taken up.
18. Continue to tighten both nuts alternately with a
spanner, one flat at a time, to a maximum of three 22
flats.
19. Carefully lever-out the differential assembly.

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24. Lift out the cross-shaft and pinions.
25. Withdraw thc four dished thrust washers.
26. Withdraw the lower differential wheel and thrust
ST597M washer.

continued
Dismantle differential
20. Add alignment marks between the crown whccl
and thc differential case for reasscmbly purposes,
then removc the fixings and withdraw the crown
wheel.

20

ST652M

8
 REAR DIFFERENTIAL -ONE TEN 151I
&:>.
...+, 27. Remove the differential bearing cones using 34. Withdraw t h e outer bearing cone.
Ir ;.:.s;,:
, .;:::;a
I
.
...,:>,,
.*
,..
”
remover 18G 47 BL and adaptors 1 and 2 and 35. Extract the pinion inner bearing cup and shim
press 47. washers from the casing. Note t h e shim washer
28. Withdraw thc shim washers fitted between the thickness. Remover S 123 A .
bearing cones and the differential casings. 36. Extract the pinion outer bearing cup from the
casing. Remover S 123 A .

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37. Remove the inner bearing cone from the pinion.
Remover 18G 47 R K and Press 47.

continued
Remove final drive pinion
29. Prevent the coupling flange from rotating and
remove the flange locknut and plain washer.
Spanner 18G 1205.
30. Support the drive pinion and remove the coupling
flange by tapping with a hide hammer.
31. Withdraw the drive pinion together with the inner
bearing cone.
32. Withdraw and discard the collapsable bearing
spacer.
33. Withdraw the oil seal, gasket and oil thrower.

Sl

....... ..
_...:. ...
7 ..:.
 151I REAR DIFFERENTIAL- ONE TEN

INSPECTION
38. Examine all components for obvious wear or
damage.
39. The bearing cones must bc a press fit on their
locations, except the drive pinion flange and
bearing which is a slide fit.
40. The crown wheel and pinion are supplied as a
matched pair and must not be interchanged
separately.
A new crown wheel and pinion matched pair may
be fitted to an original gear carrier casing if sound.
The original crown wheel and pinion, if sound,
may be fitted into a replacement casing.
41. The two parts of the differential unit casing arc
matched and must not be replaced separately.
42. Discard and renew all thrust washers.
43. Differential housings with worn thrust washer
seatings must be replaced as a pair.
- 44.-Examine the differential case to crown whecl joint -,... .
-,

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face for burrs and damage which could lead to 55. Position a suitablc dial gauge indicator on the i
*-

crown wheel run-out when fitted. casing with t h e stylus registering on the back face
of the crown wheel.
56. Rotate the differcntial and chcck the total
indicated run-out on the crown wheel back facc.
This must not exceed 0,05 mm (0.002in). If
run-out is excessive, check the mating faces for
dirt and damage; if ncccssary, select a new radial
position for t h e crown wheel. When satisl'actory,
ASSEMBLE continue with the following check.
Assemble differential unit
Differential bearing adjustment
45. Fit the differential lower wheel and thrust washer
57. Insert two levers between the casing and the
to the differcntial case. Sec illustration following
differential u n i t at one side.
instruction 23.
58. Movc the differcntial unit fully to one side of the
46. Fit the dished thrust washers.
casing; do not tilt the unit.
47. Fit the cross-shaft and pinions.
59. Rotate the differential unit to scttle the bearings,
48. Fit the differential upper wheel and thrust washer.
continuc to lever the differential to the side, then
49. Fit the differcntial upper case lining-up the marks. &T;
zero the dial gauge indicator. . I?:
50. Secure the assembly with bolts using Loctite 60. Lever the assembly fully to the other side of thc " .- ."
'..
'Studlock' grade CVX on the thrcads and tighten
casing, rotate the unit to settle the bearings, then
evenly and diametrically to 9 , l to 10,4 kgf m (66
note t h e total indicator reading.
to 75 Ibf f t ) .
51. Fit thc crown wheel to the differcntial casing. Use
Loctite 'Studlock' gradc CVX on the fixing bolt continued
threads and tighten to 13 to 13,5 kgf m (95 to
105 Ibf ft).
52. Prcss on t h e differential roller bearing cones less
shim washers, using 18G 134 DP, and leave t o
one side until required for instruction 96.
53. Fit the bearing cups to the differential.
54. Fit the differential unit and bearings to the gear
carrier casing, and rotate unit 10 centralize the
bearings. Do not fit the bearing caps.

10
 REAR DIFFERENTIAL - ONE TEN

61. Add 0,127 mm (0.005 in), for bearing pre-load, to

the total noted in the preceding instruction. ‘The
sum is then equal to the nominal value of shims
required for the differential bearings:
Shims are available in the range 0,07 mm
(0.003 in), 0,12 mm (0.005 in), 0,25 mm
(0.010 in) and 0,76 mm (0.030 in). Sclect the total
value of shims required.
62. Remove t h e differential unit and bearings and
place aside. Do not fit the shim washers until thc
subsequent ‘Differential backlash’ checks have
been made, instructions 96 to 102.

Fit drive pinion

63. Select shim washers of the same thickness v a h e as

those removed from under the pinion inner cup, ST662M
instruction 35, and place ready for fitting.
64. Position the outcr bearing rcplacer 18G 1122 G
~ detail 2, and the outer bearing cup on the press

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tool 18G 1122.
65. Locate the assembly into the pinion housing nose. 70. Press the inner bearing cone onto thc drive
pinion. 18G 47 BK, details 1 and 2 and press 47.
71. Position the pinion and bearing in the casing; omit
the collapsablc spacer at this stage.
72. Fit the outer bearing cone onto the pinion.
73. Fit the coupling flange and plain washcr and
loosely fit the flange nut.
’.. . .
74. Tighten the coupling flange locknut to remove
end-float from the pinion.
75. Rotate the pinion to settle the bearings and slowly
tighten the flangc locknut. Use a spring balancc to
obtain a torque resistance of 9,25 to 13,8 kgf cm
(8 to 12 Ibf in) to rotate t h e pinion.

continued

ST661M
-
v

I
66. Place the selected shim washcrs on to the inner
bearing cup seating.
67. Position t h e inner bearing cup in the casing.
68. Position the inner bcaring replaccr 18G 1122 G
detail 1, onto 18G 1122 and secure with the fixing
nut.
69. Hold still t h e centre scrcw and turn the butterfly
lever to draw in the bearing cups.
70%

ST638M
E
11
151I RE A R DIFFERENTIAL - ONE TEN

Drive pinion markings Drive pinion adjustment

76. Check that the serial number marked on the 80. Ensure that the pinion end face is free of raised
pinion end face matches that marked on the burrs around the etched markings.
crown wheel, 81. Remove the keep disc from the magnctized basc
77. The markings on the end face adjacent to the of dial gauge tool 18G 191.
serial number are of no significance during 82. Place the dial gauge and setting gauge 18G 191 P
servicing. or 18G 191-4 on a flat surface and zero the dial
78. The figure marked on the end face opposite to the gauge stylus on to the setting gauge.
serial number indicates, in thousandths of an inch, 83. Position the dial gauge centrally on the pinion end
the deviation from nominal required to correctly facc with the stylus registering on the lowest point
set the pinion. A pinion marked plus (+) must be on one differential bearing bore. Note the dial
set below nominal, a minus (-) pinion must be set gauge deviation from the zeroed setting.
above nominal. An unmarked pinion must be set 84. Repeat on the other bearing bore. Add together
at nominal. the readings, then halve the sum to obtain the
mean reading. Note whether the stylus has moved
up or down from the zeroed setting.

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- 88

ST649M

Sl

79. The nominal setting dimension is represented by

the setting gauge block 18G 191 P or 18G 191-4,
which is referenced from the pinion end face to Example 1
the bottom radius of the differential bearing bore.
The latter gauge is illustrated following
Rcading obtained L.H. sidc + 0.006 in if??
.r”
Reading obtained R.H. side - 0.003 in
instruction 85.
Add + 0.006 in
- 0.003 in
= + 0.003 i n
Divide b y 2 =
+ 0.003 = + 0.0015 in
- 2

Therefore subtract 0.0015 in from the shim thickness

behind the pinion inner bearing track.

Example 2
Reading obtained L.H. side + 0.006 in
Reading Chtained R.H. side - O , ( ) f i f j iE
Add + 0.006 in
- 0.008 in
ST1380M
--- = - 0.002 in
- 0.002
Divide b y 2 = ____ = - O.UO1 in
2

continued
12
 REAR DIFFERENTIAL -ONE TEN

..:.. .,.
'
85a.Where t h e stylus has moved down, the amount is 86. Before adjusting the shim thickness, check the
. ...
.....I...
.,..,
. ::
. ,,
,.!

:.
I

I - equivalent to the thickness of shims that must be pinion face marking and if it has a plus (+) figure,
removed from under the pinion inner cup to bring subtract that amount in thousands of inch from
the pinion down to the nominal position. the shim thickness figure obtained in the previous
b.Where the sty!us has moved up, the amount is instruction. Alternatively if the pinion has a minus
equivalent to the additional thickness of shims (-) figure, add the amount to the shim thickness
required to bring the pinion up to the nominal figure.
position. 87. Adjust the shim thickness under the pinion inner
cup as necessary, by the amount determined in
Illustration A. Using setting gauge 18G 191 P. instructions 85 and 86.
88. Recheck the pinion height setting instructions 82
Illustration B. Using universal setting block 18G 191-4 to 84. If the setting is correct, t h c mean reading on
the dial gauge will agree with the figure marked
NOTE: The setting block has three setting heights as on the pinion end face. For example, with an end
follows: face marking of +3, the dial gauge reading should
39.50 mm Rationalised axle indicate that the pinion is 0.003 in below nominal.
38.10 mm Pre-Rationalised axle 89. When the pinion setting is satisfactory,
30.93 mm Salisbury axle temporarily remove the pinion outer bearing.
*
Ensure that the height marked 30.93 mm is used for

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this differential.

89
/

ST646M

ST645M
90. Fit a new collapsable bcaring spdcer, flared end
outward, to the drive pinion and refit the outer
bearing.
91 Fit the pinion oil slinger
92. Fit the oil seal gasket.
E3 concinucd

ST647M
ST644M

13
 REAR DIFFERENTIAL - ONE TEN

93. Fit the pinion oil seal, lipped side first, using
general purpose grease or, where available, a
molybdenum disulphide based grease on the seal
lip, using R O 1008 to drift in the seal.
94. Fit the coupling flange and plain washer and
loosely fit a new flange nut. Secure 18G 1205 to
the coupling flange, using slave fixings.
95. Alternately tighten the flange nut and check the
drive pinion resistance to rotation until the
following figures arc achieved, as applicable:
a.Assemblies re-using original pinion bearings: 17,3
to 34,5 kgf cm (15 to 30 Ibf in).
b.Assemblies with new pinion bearings: 3 4 3 to
46,O kgf cm (30 to 40 Ibf in).
NOTE: Once the bearing spacer has started to
collapse the torque resistance build-up is rapid,
therefore check frequently, using a spring balance,
to ensure the correct figures are not exceeded,
otherwise a new collapsable bearing spacer will be
102. Fit the shim value determined in instruction 101,

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- required.
taking the shims from the pack previously
determined during ‘Differential bearing
adjustment’ checks, instructions 57 to 62
18G 47 BL details I and 2, prcss 47,lSG 134 DP.
103. Fit the remaining shims from instruction 101 to
the opposite side o f the differential. 18G 47 BL
details 1 and 2, press 47, 18G 134 DP.
104. Fit thc differential unit with shims and bearings to
the axle casing, using t h e axle spreader 1% 131 C
with pegs 18G 131 F.
105. Remove the axle spreader.
106. Fit the bearing caps in their correct position,
referring to the relationship markings on the caps
and on the axle casing.
107. Tighten the bearing caps fixings to 12,9 to
14,5 kgf m (93 to 105 Ibf ft).
ST643M
108. Mount a dial gauge on the axle casing with the
stylus resting o n a crown wheel tooth.

continued
Differential backlash checks
96. Pick up the differential unit as left after
instruction 52.
97. Fit the differential u n i t and lever the unit away
from the drive pinion until t h e opposite bearing
cup is seated against the housing. Do not tilt the
unit.
98. Install a dial gauge on the casing with its stylus
resting on the back face of the crown wheel. Zero
the gauge.
99. Lever the differential unit to engage the crown
wheel teeth in full mesh with the drive pinion
teeth. Dc net ti!t the unit.
100. Note the total reading obtained on the dial gauge.
101. From this figure subtract 0,25 mm (0.010 in) to
obtain the correct crown wheel backlash w h e n
fitted. The result indicates the value of shimming
to be fitted between the differential case and the
bearing cone at the crown wheel side of the
differential.
14
 REAR DIFFERENTIAL -ONE TEN El
109. Prevent the drive pinion from rotating and check
the crown wheel backlash which must be 0,15 to
0,27 mm (0.006 to 0.011 in). If the backlash is not
within the specified limits, repeat the differential
backlash checks, instructions 96 to 102 looking for
possible errors.
110. Fit the differential cover and new gasket, coating
both sides of the gasket with Hylomar PL 32M or
an equivalent non-setting sealant.
Torque load for fixings is 2,s to 3,5 kgf m (20 to
25 Ibf ft).
111. Reverse instructions 3 to 5 and coat the threads of
the hub driving member bolts with Loctite ST640M
‘Studlock’ grade CVX and fit and tighten the bolts
evenly. Torque: 10,O kgf m (73 Ibf ft).
112. Fit the rear axle assembly to the vehicle. 114. Where major running parts have been replaced
113. Replenish thc differential lubricating oil, (see during servicing, it is a recommended practice to
Lubrication chart). After the initial axle run, allow t h e axle assembly to ‘run in’ by avoiding,
check thc oil level and replenish as necessary to where possible, heavy loads and high speeds
- the fillerAevel plug hole. during initial running.

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DATA
Crown wheel backlash ......................................... 0,15 to 0,27 mm (0.006 toO.O1l in)
Differential bearings pre-load ................................ 0,127 mm (0.005 in)
Pinion height setting ............................................ Set using gauge 18G 191 P or 18G 191-4

Torque resistance initial setting figures

Torque to turn drive pinion and new pinion bearings ... 34,5 to 46 kgf cm (30 to 40 Ibf in)
Torque to tum drive pinion re-using the original bearings . 17,3 to 3 4 3 kgf cm (15 to 30 Ibf in)

15
 REAR DIFFERENTIAL -NINETY
FRONT DIFFERENTIAL -NINETY AND ONE TEN

OVERHAUL AXLE DIFFERENTIAL ASSEMBLY

Service tools:
18G 1205 flange holder tool;
18G 191 pinion height setting gauge;
18G 191-4 universal setting block;
18G 47-6 pinion head bearing removerheplacer;
LST 106 oil seal replacer; or
RO 262757A extractor for pinion bearing caps;
RO 262757-1 replacer-use with RO 262757A;
RO 262757-2 adaptor tail bearing cap replacer;
KO 530105 spanner-differential flange and carrier
bearing nuts; ST505M /
RO 530106 bracket for dial gauge and indicator;
MS 47 press 9. Withdraw the pinion complete with pinion head
bearing and outer bearing shims. Withdraw the
DISMANTLE shims.
It is essential that differential components are markcd 10. Remove the pinion flange oil seal, spacer and
1 in their original positions and relative to other bearing. Discard the oil seal.

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components so that, if refittcd, their initial setting is
maintained. Note that the bcaring caps must not be
interchanged.

1. Remove the differentlal assembly from the axle.

2. Drift out the roll pin sccuring the bearing n u t
locking fingers to the bcaring caps. Remove the
locking fingers.
3. Slacken the bearing cap bolts and mark the caps for
reassembly.
4. Using service tool R O 530105, remove the bearing
adjusting nuts. ST506M
5. Remove the bearing cap bolts and bearing caps.
6. Lift out of the crown whecl, differential unit and 11. Using service tool R O 262?57A, remove the pinion
bearings. head bearing track and shim and drift out thc outer
bearing track from t h e differential housing.

ST
7. Remove the split pin securing the pinion flange
nut.
8, R~~~~~ the pinion flange n u t using service tool 12. Remove the pinion head bearing with service tool
18G 1205 to restrain the flange. MS 47 and adaptor 18G 47-6.

16
 REAR DIFFERENTIAL -NINETY
FRONT DIFFERENTIAL -NINETY AND ONE TEN E
1
...... -
., ..,.
"..~H: ASSEMBLE
,....,. ...
...,.
.
.

Differential gears

21. Fit the differential gears to the differential housing.

22. Fit the differential cross shaft and retaining circlips.

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ST508M

13. Remove t h e bolts and washers securing the crown

wheel t o the differential flangc. Withdraw the
crown whecl.
14. Remove the differential carrier bearings.
15. Remove the circlips securing the differential cross
shaft. Extract the cross shaft.
16. Withdraw thc differential gears and pinions.
17. Thoroughly clean all components. STSIOM

23. Check the gear for freedom of rotation and

backlash. Nominal backlash should be present.
Excessive backlash will necessitate renewal o f the
gears and/or the differential housing. No provision
is made for backlash adjustment.
24. Check that the serial number marked on the pinion
end face matchcs that marked on the crown wheel.
7-5. Ensuring that the differential housing flange and
crown wheel are, thoroughly clean fit the crown
wheei. Fit the cmwn wheel bolts and washcrs and
evcnly tighten.
26. Fit the carrier bearings using a suitable press or
drift and assemble the tracks to the bearings.

ST509M
25
INSPECTION
18. Check all bcarings for wear and/or pitting.
19. Check all gears for wear, scuffing, pitting and
damaged teeth.
26
20. NOTE. The crown wheel and pinion are supplied as
a matched set, also the pinion housing and bearing
caps.

ST511 M
17
 REAR DIFFERENTIAL -NINETY
51 FRONT DIFFERENTIAL - NINETY AND ONE TEN

27. Place the differential housing complete with crown

wheel and bearings in the pinion housing.
28. Fit the bearing caps and bolts. Do not fully tighten
the bolts.
29. Fit the bearing adjusting nuts and adjust to obtain
zero end-float.
30. Tighten the bearing cap bolts.

ST514M
36. Fit the pinion head bearing to thc pinion using
LI
ST512M service tool 18G 47-6.

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4
31. Using a dial gauge check thc crown wheel for
run-out. This should not exceed 0,10 mm
(0.004 in). If excessive run-out is recorded remove

w
the crown wheel and examine crown wheel and
mounting flange for burrs, grit, etc. Refit the
crown wheel and recheck. Run-out, attributable to
a buckled or damagcd differential housing flange
can be corrected only by renewing the differential
gear housing.
32. When satisfied that run-out is within the specified
limits remove the differential housing from the
pinion housing.
33. Remove the crown wheel bolts and refit them using
Loctite 'Studlock'. Evcnly tighten the bolts to t h e
correct torque.

37. Enter the pinion into its location in the pinion

housing. Do not fit the shims for bearing pre-load
at this stage.
38. Fit the outer bearing and spaccr.
39. Fit the driving flange, washer and n u t .

34. Fit the pinion head bearing track and the original
continued
shim to the pinion housing using service tools
R O 262757A and R O 262757-1. If the original
shim was damaged or mislaid use a new shim of at
least 1,27 mm (0.050 in) thickness.
35. Fit the pinion outer bearing track to the pinion
housing with service tool KO 262757A and
R O 262757-2.
NOTE: Instructions 34 and 35 are carried out in one
operation as illustrated.
18
 REAR DIFFERENTIAL -NINETY
FRONT DIFFERENTIAL - NINETY AND ONE TEN

.. _,.
'. .... Drive pinion adjustment
..,.. ::...,
....,./.,i;
.'.:I
45. Ensure that the pinion end face is free of raised
burrs around the etched markings.
46. Remove the keep disc from the magnetised base of
dial gauge tool 18G 191.
47. Place the dial gauge and setting block on a flat
surface and zero the dial gauge stylus on the setting
block.
NOTE: The setting block has three setting heights
as follows:
39,50 mm Rationalised axle
38,10 mm Pre-Rationalised axle
30,93 mm Salisbury axle
Ensure that the height marked 39,50 mm is used
ST516M for this differential.

. 40. Do not fit the oil seal at this stage.

41. Tighten t h e pinion flange n u t slowly until the force

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required to rotate the pinion is 23 to 40,25 kgf cm
. I .

. ..
(20 to 35 Ibf in). This will pre-load the bearings in
order to check the pinion height dimension.
NOTE: If using original bearings, which are bedded
in, the pre-load figure is 11,5 to 17,25 kgf cm (10 to
15 in Ib).

Drive pinion markings

42. The markings on the end face adjacent to the serial
number are of no significance during servicing.
43. The figure marked on t h e end face opposite to the
seripl number indicates, in thousandths of an inch, ST518M
the deviation from nominal required to correctly
set the pinion. A pinion marked plus (+) must be
set below nominal, a minus (-1 pinion must be set 48. Position the dial gauge centrally on the pinion end
above nominal. An unmarked pinion must be set at face with the stylus registering on the lowest point
.
.' ..,
.I-. nominal. on one differential bearing bore. Note the dial
. .
44. The nominal setting dimension is represented by
, I

gauge deviation from the zeroed setting.

the setting gauge block 18G 191-4 which is
referenced from t h e pinion end face to the bottom
radius of the differential bearing bore.

43

ST517 I I continued

;. .._
...
. . ..<..
%

19
 REAR DIFFERENTIAL -NINETY
FRONT DIFFERENTIAL -NINETY AND ONE TEN

49. Repeat on the other bearing bore. Add together 58. Tighten the pinion flange nut to the specified
the readings then halve the sum to obtain the mean torque. The force required to rotate the pinion
reading. Note whether the stylus has moved up or shaft should be within 23 to 40,25 kgf cm (20 to
down from the zeroed setting. 35 Ibf i n ) when initial inertia has been overcome.
Change the bearing pre-load shim as necessary to
a. Where t h e stylus has moved down, the amount is obtain this requirement. A thicker shim will reduce
equivalent to the thickness of shims that must be pre-load; a thinner shim will increase prc-load.
removed from under the pinion inner track to bring NOTE: If using original bearings, which are bedded
the pinion down to the nominal position. in, the pre-load figure is 11,5 to 17,25 kgf cm (10 to
b. Where the stylus has moved up, the amount is 15 in Ib).
equivalent to the addition thickness of shims
59. Remove the pinion flange.
required to bring the pinion up to the nominal
position. Fitting Pinion Oil Seal -latest type FRC 8220
CAUTION A - When fitting the latest type oil seal
50. Before adjusting the shim thickness, check the FRC 8220 in place of the early type FRC 4586 the latest
pinion face marking and if it has a plus (+) figure, mudshield FRC SI54 must be fitted in place of the early
subtract that amount in thousandths of an inch type 236072.
from the shim thickness figure obtained in the Also seal replacer ISG 1382 must be used to fit the early
previous item. type oil seal FRC 4586. This tool must not be used to fit
- 51. Alternatively, if the pinion has a minus (- ) figure, latest seal FRC 8220.

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add the amount to the shim thickness figure. CAUTION B - Before fitting the new seal to the
Adjust t h e shim thickness under the pinion head differential, examine the seal to ensure that it is clean,
bearing track as necessary. undamaged and that the garter spring is properly
52. Recheck the pinion height setting. If the setting is located. A small scratch on the seal lips could impair its
correct, the mean reading on the dial gaugc will efficiency.
agree with the figure marked on the pinion end
60. Coat thc outer diameter of the new seal with an
face. For example, with an end face marking of +3,
all-purpose grease and fit the seal, lip side leading
the dial gauge reading should indicate that the
squarely on the pinion nose housing and drive the
pinion is +0.003 in.
seal into position flush with the end face of the
housing using seal replacing tool LST 106
Bearing pre-load adjustment
53. Remove the pinion flange, pinion, outer bearing
and spacer.
54. Slide new shims, of the same thickness as the
originals (bearing pre-load) into position on the
pinion shaft. If the original shim was damaged or
mislaid use a n e w shim of at least 4,06 nim
(0.160 in) thickness.
55. Enter the pinion in its location in t h e pinion
housing and fit the outer bearing and spacer.
56. Fit the driving flange, washer and nut.
57. Do not fit the oil seal at this stage.
RR968M
61. Lightly lubricate t h e seal lips with EP90 oil. Fit the
distancc piecc and flange and secure with washer
and n u t . Tighten the n u t to the specified torque
and fit a new split pin.

ST1405M

20
 REAR DIFFERENTIAL -NINETY
FRONT DIFFERENTIAL -NINETY AND ONE TEN 51
?;:$,:-:. 62. Place the differential housing in the pinion 67. Tighten the left hand nut slowly until it contacts the
?I .a.
.;:,.:#
,’”.?N
“Wi’
housing. bearing. Continue turning the left-hand nut until a
63. Fit the bearing caps and bolts. Do not fully tighten backlash of 0,10 to 0,17 mm (0.004 to 0.007 ins) is
the bolts. achieved. Do not slacken the right-hand n u t at any
64. Fit the bearing adjusting nuts. time, otherwise thc bearing preload will be
affected.
68. Fit the locking fingers and roll pins. If necessary,
tighten the adjustment nuts slightly to align the
locking finger with a slot.

ST522M

T I, ’

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65 Using service tool 530105, slacken the lcft hand
bearing adjustment nut (as illustrated) to produce
end float.
66. Tighten the right hand nut until crown wheel/
pinion backlash is just removcd.
69. Evenly tighten the bearing cap bolts to the
specified torque.
70. Rcchcck crown whecl/pinion backlash.
66 71. Lubricate the bearings and gears.

ST523M
. . :.,
.......
.....
,..
....
.....

DATA

Pinion bearing pre-load ........................................ 23 to 40,25 kgf cm (20 to 35 Ibf in)

Crown wheel run-out ........................................... 0,10 m m (0.004 in)
Crown wheel/pinion backlash ................................ 0,10 to 0,17 m m (0.004 to 0.007 in)

:...5.. ..>
.:..:. . ...,
‘2, ,
.:
’

21
 .-."
.'::.. ....

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