[Rebuild of the LT77 Gearbox]

On 2/15/2010 at 11:37 PM, shauniedawn said:

Hiya everyone.

I'm a relative newbie to posting on this forum, but have read posts and technical topics for a while.

Inspired by the technical topics posted by Les Henson (which I've used), I decided that I'd do one for a TR7 forum that I'm active on, covering a rebuild of the LT77.

Anyhow. I messaged Les last week to ask him how to upload this into the archive section on this site - but unfortunately, I've not heard back from him, so thought I may as well post the thread here.

Now. This is a Land Rover box I'm overhauling, but I've written it for the TR7 audience. Not that that makes much of a difference, as the boxes are almost identical, but just explains the TR7 references throughout.

Kind regards,

Shaun.

Hiya.

I bought another Land Rover last summer. I got it for a good price, as it had a messy oil leak from the engine/gearbox area. It was hard to tell where exactly it was coming from, as there was oil all over the place.

Anyhow, I ran it for a while, but the dripping really started to get on my nerves, so I decided to take the engine out . . . .

Motor came out no problem (left the gearbox in the car). Cutting to the chase, there were a few oil leaks, but the main problem was that on this Land Rover reconditioned engine (only done 15K ish), the rear crankshaft oil seal had been put in the wrong way round! Shocking. I had the sump, ladder, oil pump and front case all off. New gaskets and seals, timing belt etc.

So the engine was all washed off, and nice and clean – but the gearbox looked filthy. So I decided to drop the box out too, and give it a good clean. Bloody awkward thing to remove due to the very unbalanced nature of it.

http://farm4.static.flickr.com/3444/3960009625_747f32ac27_b.jpg

I spent the best part of a day cleaning the gearbox and transfer box off – but the results were worth it.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_0899.jpg?t=1265490701

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_0896.jpg?t=1265490773

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_0898.jpg?t=1265490744

On inspection, I could see that there was a little oil leaking here and there. So I thought – “What the hell. I’ll split it and treat it to a few new oil seals and gaskets whilst I’ve got it out.” And boy, was I pleased that I decided to do this!

When I got the transfer box parted from the gearbox I found that the mainshaft splines were about worn through (ready to lose drive), and the transfer box input gear splines were also worn out. I’d have no sooner got this all back together, and the bloody thing would have sheared the final bits of the splines off, and left me with no drive. And of course, it would all have to come out again.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8226.jpg?t=1265490904

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8228.jpg?t=1265490936

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8231.jpg?t=1265490956

This was a known fault by the way on Defenders/Discoverys of this age. The later input gears were modified with lubrication holes to stop the wear.

Essentially this gearbox is the same as found in our 5 speed TR7s – it’s an LT77. There are a few minor differences here and there – but not much. So I thought it would make an interesting topic.

Here goes…

As you can see, the selector housing is different to the TR7.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8234.jpg?t=1265491035

Remove it

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8347.jpg?t=1265491080

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8348.jpg?t=1265491134

Again, not on TR7, but you have to do it! Remove snap ring.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8349.jpg?t=1265491217

Remove oil seal collar. It has a groove machined in it to pick up on it for pulling – it’s tight!

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8350.jpg?t=1265491244

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8351.jpg?t=1265491283

Remove bolts and slide off aluminium housing.

%5B/img%5D

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8354.jpg?t=1265491333

Remove oil pump gears – they were worn, but very good for 115,000mls. Much better than most TR7 gearboxes I’ve split.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8356.jpg?t=1265491392

Upend the gearbox.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8359.jpg?t=1265491409

Picking up on one of the centre plate bolt holes, lock the 5th gear – I used a bit of scrap. As the nut is staked, it’s quite tight. This isn’t a nut on the TR7 box – it’s a press on collar that you have to pull off - if I remember correctly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8361.jpg?t=1265491457

Remove selector and then 5th gear circlip.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8362.jpg?t=1265491525

Remove selective spacer and 5th gear from mainshaft (3rd motion shaft).

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8365.jpg?t=1265491696

This is different to TR7 – 5th gear has a split caged bearing. Open up cage and remove.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8366.jpg?t=1265492135

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8367.jpg?t=1265492184

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8369.jpg?t=1265492209

Lift off 5th gear from layshaft Can't remember if I needed a puller to do this. Or whether employed the two pry bars again - sorry, no photo.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8370.jpg?t=1265492497

Invert casing and remove front cover, selective washers and gasket.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8371.jpg?t=1265492565

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8372.jpg?t=1265492608

Remove selector shaft spool retainer.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8373.jpg?t=1265492629

Lift off casing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8374.jpg?t=1265492639

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8375.jpg?t=1265492657

Remove reverse shaft, thrust washer, reverse gear and spacer. Reverse lever pin, lever and slipper pad.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8376.jpg?t=1265492780

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8377.jpg?t=1265492808

Lift off constant pinion shaft (1st motion shaft).

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8378.jpg?t=1265492845

Remove layshaft.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8380.jpg?t=1265492887

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8381.jpg?t=1265492959

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8382.jpg?t=1265492975

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8383.jpg?t=1265492991

Unscrew plug and remove detent ball.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8384.jpg?t=1265492930

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8385.jpg?t=1265493045

Remove mainshaft gear cluster complete with selectors.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8386.jpg?t=1265493024

Centre plate – push out bearing races (push fit only).

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8387.jpg?t=1265493105

Hold CPS in vice and pull out outer bearing race. I used my slide hammer as I don’t have an internal bearing puller.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8388.jpg?t=1265493127

Flip over and pull other bearing race.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8389.jpg?t=1265493141

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8390.jpg?t=1265493164

Fitting new bearing – heat CPS to expand.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8426.jpg?t=1265493206

Drop in new bearing outer, making sure it’s seated by tapping it home using old bearing as a sized drift/tool.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8427.jpg?t=1265493228

I used the old bearing inner to go into the end of my ‘bearing fitting tube” (a piece of pipe). Ready to use to tap new bearing home.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8428.jpg?t=1265493294

Once CPS has cooled, warm new bearing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8429.jpg?t=1265493345

Once warmed, drop onto CPS. Use tool to make sure bearing has seated properly. You find that these bearings simply fall on once heated as they expand a fair bit. But I like to be able to check that they have gone all the way home. I usually use the old bearing races as part of the tool as they are the correct size.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8430.jpg?t=1265493413

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8431.jpg?t=1265493434

Ok. Onto the mainshaft now. Support in vice.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8437.jpg?t=1265493473

Remove circlip.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8439.jpg?t=1265493492

Pull off bearing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8440.jpg?t=1265493512

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8441.jpg?t=1265493871

Slide off gear bush, spacer, cone, inner and outer baulk rings. I put a tie wrap around them to keep them all together.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8442.jpg?t=1265493941

This is where/how you check the synchro for overall wear. You need to be able to get a minimum of a 15 thou (0.015”) feeler gauge in the gap when the synchro is properly seated. Obviously, check visually for wear, chunks missing etc.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8443.jpg?t=1265493975

Slide off gear and bearing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8445.jpg?t=1265493992

Turn mainshaft round and pull off small CPS end bearing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8447.jpg?t=1265494009

Remove gear assembly. Tie wrap together.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8448.jpg?t=1265494029

That’s the shaft bare now. Here’s my replacement mainshaft and transfer input gear next to the old ones. You can see one of the 4 drillings in the ‘modified’ input gear here. Clean off new shaft and blow out all oil galleries with compressed air I'm ready for re-assembly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8449.jpg?t=1265494048

Here’s the layshaft.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8450.jpg?t=1265494065

Pull the bearings off as per all the others.

Here’s the Land Rover shaft next to a TR7 one. TR7 in the foreground with smaller straight cut reverse gear.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8540.jpg?t=1265494159

Heat new bearings and fit to mainshaft. Slide hammer to check bearings seated.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8541.jpg?t=1265494246

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8542.jpg?t=1265494263

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8543.jpg?t=1265494293

Now to re-assemble to mainshaft. It’s basically the reverse of the dismantling. Lubricate bearings. (By the way. The manual describes in detail how to dismantle each synchro/gear assembly to check for wear and measure end float - where necessary using sized selective spacers blah blah blah. All bearings heated before fitting to enable assembly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8529.jpg?t=1265494470

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8530.jpg?t=1265494487

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8531.jpg?t=1265494499

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8532.jpg?t=1265494514

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8533.jpg?t=1265494537

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8534.jpg?t=1265494552

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8535.jpg?t=1265494567

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8538.jpg?t=1265494595

So. Here’s the assembled mainshaft (rear) with a TR7 mainshaft in the middle, and the buggered shaft in the foreground. You can see the slight differences between the shafts. On the TR7 shaft I’ve fitted the spacer you have to machine up to check for endfloat on 1st gear – just in case you were wondering what it was.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8539.jpg?t=1265494610

Onto the assembly into the centre plate. As you can see. All washed off with gasket faces cleaned. Fit bearing outer races – push fit only.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8544.jpg?t=1265494629

Fit selector forks to mainshaft, ensuring synchro’s are in neutral position.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8545.jpg?t=1265494648

Fit mainshaft and selectors as a single unit to the centre plate.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8546.jpg?t=1265494667

Fit layshaft.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8547.jpg?t=1265494681

Fit reverse gear assembly and retain with bit of metal. This is to stop the reverse shaft falling out whist continuing with assembly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8548.jpg?t=1265494700

Fit 4th gear baulk ring and CPS.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8549.jpg?t=1265494728

Make sure the selector spool is in neutral position and fit the detent ball, spring and plug.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8550.jpg?t=1265494772

Cleaned out casing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8551.jpg?t=1265494806

Fit gasket.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8552.jpg?t=1265494824

Fit casing (carefully).

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8553.jpg?t=1265494841

Fit outer bearing races – push fit only.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8555.jpg?t=1265494868

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8556.jpg?t=1265494883

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8557.jpg?t=1265494952

Fit new o-ring and fit spool retainer to casing, securing set screws with Loctite or similar.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8574.jpg?t=1265494969

Oh yes – Loctite in detent plug.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8575.jpg?t=1265494985

Stake plug.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8576.jpg?t=1265495000

Now it’s time to make a tool to hold the front bearings in place, but mainly to take the force (as opposed to the bearing) on the layshaft when fitting the tight 5th gear assembly later.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8580.jpg?t=1265495041

The manual gives dimensions. Take a piece of bar. Marked out and centre-popped ready for drilling.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8581.jpg?t=1265495059

Spot drill.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8582.jpg?t=1265495083

Drill out.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8583.jpg?t=1265495125

Now to make the distance piece that sits under this bar and picks up on the end of the layshaft.

Bit of scrap bar.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8584.jpg?t=1265495141

Part off disc 3.5mm x 25mm

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8588.jpg?t=1265495196

Disc and bar ready. You could just use a few washers of course.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8589.jpg?t=1265495216

Disc ‘stuck’ on the end of the layshaft with a bit of grease to keep it in place.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8590.jpg?t=1265495257

Bolt bar across.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8591.jpg?t=1265495271

Invert box and remove reverse gear shaft holding ‘tool’.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8592.jpg?t=1265495287

I held the box in the vice gripping onto the layshaft support bar I’d just fitted.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8617.jpg?t=1265495344

You now have to drive 5th gear onto the end of the layshaft. So needed to make a tool to help.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8618.jpg?t=1265495384

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8619.jpg?t=1265495414

Used an old bearing race and a bit of pipe fitting. The bit above is a plug to go in the end of the pipe collar (to bash with a 3lb hammer!!!).

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8620.jpg?t=1265495458

Heat gear.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8621.jpg?t=1265495482

Bash the bugger home! You’ll see I fitted a bit of pipe over the mainshaft. Just in case one of my heavy hammer blows went off course – didn’t want to make a big dent in my new shaft!

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8622.jpg?t=1265495505

As I didn’t have a new retaining nut I took a few thou off the original so it would stake up into new metal when re-fitted. Clocking the nut in the chuck before machining.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8624.jpg?t=1265495570

Machined.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8625.jpg?t=1265495548

Fitted – loosely.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8626.jpg?t=1265495632

Fit 5th gear bearing cage.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8627.jpg?t=1265495667

Followed by assembly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8628.jpg?t=1265495687

And baulk ring/synchro assembly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8629.jpg?t=1265495703

Fit 5th gear ‘retaining’ tool and tighten nut to 230Nm.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8633.jpg?t=1265495842

Measuring the inner member synchro clearance (up to 0.002”). Use selective washer to achieve correct tolerance between it and the circlip.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8631.jpg?t=1265495870

Stake nut.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8634.jpg?t=1265495889

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8637.jpg?t=1265495919

Fit 5th gear selector fork assembly.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8639.jpg?t=1265495940

Fit oil pump drive square to end of layshaft.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8640.jpg?t=1265495957

New and old oil pump gears. These gears were the best I’ve evere seen. Other TR7 boxes I’ve stripped have has bits of swarf and chunks missing on occasion.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8717.jpg?t=1265495983

Fit gears to casing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8718.jpg?t=1265495998

Line up oil pump square drive with the oil pump. Fit gasket and offer up casing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8719.jpg?t=1265496011

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8721.jpg?t=1265496119

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8722.jpg?t=1265496175

Remember the TR7 casing is a bit different with a support roller bearing and the output flange, which is held on with a nut. Here’s a flange holding tool I made to hold it whilst the nut is tightened.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8757.jpg?t=1265496061

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8752.jpg?t=1265496077

But the Land Rover is a bit different as it has a collar pressed onto the mainshaft that seals the casing. The inner is sealed with an o-ring, the outer of the collar direct onto a regular oil seal.

Fitting o-ring.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8723.jpg?t=1265496211

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8725.jpg?t=1265496237

Fitting oil seal.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8734.jpg?t=1265496270

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8735.jpg?t=1265496291

Here’s the collar.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8736.jpg?t=1265496304

Now. I didn’t want to heat the collar to get it on as I would be likely to damage either the seal or the o-ring or both. So a different approach was needed.

Here’s my assembled bits and bobs to do the job.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8676.jpg?t=1265496353

Part off bit of scrap tube.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8677.jpg?t=1265496383

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8678.jpg?t=1265496398

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8679.jpg?t=1265496443

As this was chromed, needed to machine a bit of the chrome off where I was going to weld.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8680.jpg?t=1265496457

Machining an ‘end’ for the tube.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8682.jpg?t=1265496472

End fitted into tube – you can just see the join.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8684.jpg?t=1265496493

This nut is to pick up on the threaded end of the mainshaft. It’s an odd size at 18mm. Machined off nyloc bit.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8685.jpg?t=1265496518

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8686.jpg?t=1265496547

Weld nut onto end of studding.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8687.jpg?t=1265496562

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8688.jpg?t=1265496584

Weld end into tube.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8690.jpg?t=1265496612

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8693.jpg?t=1265496633

Drill clearance hole for studding to pass through.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8694.jpg?t=1265496648

Take off rough edge.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8695.jpg?t=1265496666

I was going to use that welded on nut as my holding point for this tool, but decided against that, and ground the nut off.

Found a nut instead.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8696.jpg?t=1265496703

Bored nut out to OD of the tube.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8698.jpg?t=1265496723

Slid nut onto tube.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8700.jpg?t=1265496737

Welded into place.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8705.jpg?t=1265496761

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8708.jpg?t=1265496802

Finished tool ready for action!

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8714.jpg?t=1265496779

Screw nut/studding onto end of mainshaft.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8737.jpg?t=1265496823

Screw nut down studding to force collar onto shaft. Worked a treat! And no damage to seals []

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8738.jpg?t=1265496839

Better photo.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8739.jpg?t=1265496865

Collar fitted.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8741.jpg?t=1265496879

Fit snap ring to shaft.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8742.jpg?t=1265496896

Now we’re up to sorting the endfloat/preload on the main and layshafts. Invert gearbox.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8743.jpg?t=1265496911

Remove holding tool.

Fit spacer to mainshaft, and measure clearance as per manual. Land Rover manual shows you how to measure using feeler gauges.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8744.jpg?t=1265496950

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8745.jpg?t=1265496972

I preferred to use a DTI as per the TR7 manual though.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8750.jpg?t=1265497093

Remove packing piece, and repeat for layshaft. You have to use the feeler gauge method for this shaft.

Replace shims as appropriate. I needed to buy one, but managed to grind another down on a diamond stone.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8751.jpg?t=1265497121

Fit correct size shims, oil seal to housing, and then housing to casing.

These next few pics are just of the gear leavers going on (all stripped and re-greased).

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8758.jpg?t=1265497338

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8759.jpg?t=1265497352

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8761.jpg?t=1265497365

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8762.jpg?t=1265497379

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8763.jpg?t=1265497396

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8765.jpg?t=1265497511

Bell Housing.

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8776.jpg?t=1265497532

Then the clutch lever arm. There is a ‘heavy duty’ one listed for the Land Rover. In reality, it’s identical with a bit of 1” strip welded in place. The TR7 and 8 can suffer from the same fate as the Land Rover with the pivot pin wearing its way gradually through the arm. This little modification gives it a few more years use…

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8781.jpg?t=1265497604

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8783.jpg?t=1265497619

http://i422.photobucket.com/albums/pp305/shauniedawn/LT77%20Gearbox%20Overhaul/DSC_8792.jpg?t=1265497637

Hope you enjoyed the thread []

Shaun.

Cracking job, all to often I wince at some of the things done to complete a job but even the machining & welding looked good.

[LT77 1st gear rattles]

Hi, 
I wonder if the rattle I get occasionally while in first gear is a common issue and is there a recognised fix? It sounds like it is trying to jump out of gear but it only happens now and again!..

Regards

Paroak