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Replacing an LT77 in a Discovery inc LT230/Clutch


white90
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part2

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If you are in the right position you will be able to see and carefully guide the input shaft through the splines and into the clutch. If it stops dead a couple of inches away from the engine, then turn the gearbox shaft to align the splines and the gearbox should then slide all the way on.

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Put a few nuts on the thread to keep the gearbox in place and then tighten them. Replace the slave cylider - making sure the rod goes through the hole in the dust cover.

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You can test the clutch by pressing the pedal. Replace and tighten all the bell housing bolts, remove the jack and put it under the gearbox and raise it a small amount.

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The transfer case has a seal that fits over a land on the gearbox shaft, so grease the land.

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There's a possibility that the transfer case seal could have been damaged when removing it from the gearbox or just as a precaution - replace it.
The old seal easily levers out - be careful not to damage the alloy housing.

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The end of a hub nut box spanner is exactly the right size to press the new seal in.

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Just slightly lower than the surrounding metal.

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Remove the gearbox crossmember.
The transfer case is a very awkward shape and getting the balance right is very difficult. Try to position yourself so that you can make sure that you don't damage the new seal as you slide it onto the gearbox. Once again if it comes to a dead stop - you will have to turn one of the prop flanges to align the splines of the input gear and shaft. The transfer case should then slide all the way on. Replace the 5 bolts and but and tighten them. Jack the gearbox up as high as it will go, and replace the mounting.

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Replace the crossmember and tighten all the bolts/nuts (13mm or 17mm). Don't forget that the speedo cable clip goes on one of them.

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Reattach the speedo cable - making sure it's fully home before tightening the nut. Then the handbrake cable.

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A smear of gun gum or similar on the exhaust joint. Tighten the nuts evenly to ensure a good seal, and then bolt up the exhaust mounting.

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Lower the transmission down - making sure the holes all line up - replace the 17mm nuts/bolts.

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The filler plug is on the drivers side of the gearbox - a 13mm spanner is the right size to undo it. This is also a level indicator, so fill with Dextron 3 or equivalent, until it starts to dribble out of the hole.

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The transfer case has the same filler/level arrangement. The square key plug can be undone with a 1/2" drive ratchet.

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Use EP80/90 oil in the transfer case.
Attach both breather pipes - making sure there's a copper washer either side of the banjo fitting, attch the wires to the diff lock switch, reverse switch, and the pivot point for the transfer lever rod (there are two thin plastic washers that go either side of the eye - if they are loose, apply a small amount of grease to keep them in place).

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Grease the mechanism of the transfer lever inside it's housing and then bolt it back down, and attach the two link rods - making sure the previously made marks line up.

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Reassemble the tunnel cover rubber and attach it with pop rivets.

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Attach the hand brake cable, put the foam insulation back on and then the tunnel cover.

That's it. Take the vehicle for a test drive - the gearbox may be a little stiff initially, but will soon settle in. The gearchange is very accurate, so expect a few mistakes until you get used to it.
A few things to remember -
If you need to stop for a break, don't do it with the transfer box or gearbox not bolted on properly. They could fall off and be damaged. Try to make the time the gearbox and end engine are only supported by the engine mounts - they could get split if you don't get on with it. It takes a lot of physical effort to remove the transmission, so take a break after removing/replacing them. Use the recommended oils - the wrong type will damage the transmission and may cause it to fail prematurely and require replacement. If you can get anyone to help you with at least the heavy lifting, then do so. If you slip or something goes wrong, you can be seriously injured.
I had to do it on my own - I have no mates biggrin.gif


Les. smile.gif

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