picpoki Posted February 21, 2010 Share Posted February 21, 2010 Will you also rebuild LT230 perhaps? Quote Link to comment Share on other sites More sharing options...
shauniedawn Posted February 21, 2010 Author Share Posted February 21, 2010 Will you also rebuild LT230 perhaps? I'm hoping I won't have to!!! Quote Link to comment Share on other sites More sharing options...
picpoki Posted February 21, 2010 Share Posted February 21, 2010 Yes, but you would do a huge favour to us Quote Link to comment Share on other sites More sharing options...
stelaras Posted February 26, 2010 Share Posted February 26, 2010 nice job , both rebuild and doc.. i did the same job to my lt77 and gone nt so good a backlash in 1st and less in 2nd make me think riconsidering to change job , i am architect have any idea what gone wrong? Quote Link to comment Share on other sites More sharing options...
shauniedawn Posted February 27, 2010 Author Share Posted February 27, 2010 nice job , both rebuild and doc.. i did the same job to my lt77 and gone nt so good a backlash in 1st and less in 2nd make me think riconsidering to change job , i am architect have any idea what gone wrong? I'm sorry, but I don't understand the question. Quote Link to comment Share on other sites More sharing options...
picpoki Posted February 28, 2010 Share Posted February 28, 2010 I took my transfer and gearbox apart. The main shaft and the input gear are completely worn out. After 180.000km. Next week I`m taking it to Ashcroft... Quote Link to comment Share on other sites More sharing options...
shauniedawn Posted March 2, 2010 Author Share Posted March 2, 2010 I took my transfer and gearbox apart. The main shaft and the input gear are completely worn out. After 180.000km. Next week I`m taking it to Ashcroft... I was hoping to inspire more of you to do your own! Quote Link to comment Share on other sites More sharing options...
picpoki Posted March 3, 2010 Share Posted March 3, 2010 Well, I know my limits I think it will be a lot cheaper if Ashcroft rebuild it. And faster too. Quote Link to comment Share on other sites More sharing options...
welling4x4 Posted November 14, 2011 Share Posted November 14, 2011 Great work! But I`m still taking my LT77 to aschroft U must be made of money Quote Link to comment Share on other sites More sharing options...
parchwba Posted June 13, 2013 Share Posted June 13, 2013 Hello Shaun, this post is soooo helpful! It has inspired me to fix my gearbox as I can't select any gears. Me thinks it might be the selector's faulty somewhere. I've gotten the gearbox on me workbench and the shafts look brand new, so I'm hoping it might be something simple. Anyway, do you think a hydraulic puller is needed to remove the first bearing or would a normal puller be ok? I'm up for the challenge, if I can do it, anyone can. Thanks again, Mark. Quote Link to comment Share on other sites More sharing options...
colin rolin Posted October 18, 2013 Share Posted October 18, 2013 Anyone else having issues seeing the pictures? I'm about to rebuild my spare lt77 and the pictures would help me a lot! Quote Link to comment Share on other sites More sharing options...
ejparrott Posted October 23, 2013 Share Posted October 23, 2013 I've just had a quick look through and all seems ok Quote Link to comment Share on other sites More sharing options...
reb78 Posted October 23, 2013 Share Posted October 23, 2013 They were missing the other day, but now they are back. Thats the problem with photobucket - i beleive if a user doesnt log in for some time, the pictures get removed?? Is there anyway of the Mods saving these pics to the forum as this is a really useful thread, so it would be a shame to lose it if shauniedawn ever closes his photobucket account.. Quote Link to comment Share on other sites More sharing options...
dailysleaze Posted October 23, 2013 Share Posted October 23, 2013 They disappeared due to excessive bandwidth usage on the photobucket account - too many people looking at this thread! Quote Link to comment Share on other sites More sharing options...
TNewman Posted June 18, 2014 Share Posted June 18, 2014 Morning Folks, Just bumping the previous post. Photos are down again. Any help is really appreciated. Cheers, Tod. Quote Link to comment Share on other sites More sharing options...
L90DGM Posted November 13, 2015 Share Posted November 13, 2015 Alright Newbie Ive just purchased a LT77 gearbox to refurb then fit as I use my landy everyday Unfortunately I cant see the pictures . is there any chance of putting the whl thing in a word document and emailing it to me ? Ta Dom Quote Link to comment Share on other sites More sharing options...
peterg123 Posted May 18, 2016 Share Posted May 18, 2016 What a great Article however, when measuring layshaft and mainshaft end play using the end cover, you mention that the LT77 workshop manual shows one how to use the feeler gauge method, but you preferred the TR7 method with a dial gauge. Well, I have looked in various workshop manuals and all I ever see is the dial gauge method. Can you please explain how the feeler gauge method, using the end plate and various shims, would work? I have done my mainshaft with a "guessed" spacer of, to find the end float is 005", meaning I need to add a 003 shim to get it to the required 002" ( which is I think correct!? Kindly comment). But I am buggered as to how I can measure the layshaft as it is a blind fitting in the end cover. I have not dismantled all my box as this is not required..just setting the float and preload. Wil I have to take off the middle cover to measure the layshaft float? If you can help, would appreciate. Peter in Nairobi Quote Link to comment Share on other sites More sharing options...
shauniedawn Posted May 28, 2016 Author Share Posted May 28, 2016 Hi - it's 6 years or so since I did this so can't remember much of it now! However, I've checked the PDF Land Rover manual I have and it describes the method. If you PM me you email address then I'll happily forward it on. Shaun Quote Link to comment Share on other sites More sharing options...
Jocklandjohn Posted June 5, 2016 Share Posted June 5, 2016 I've got a leak on the side of my gearbox - it's a later model LT77 (which I think is LT77s). The weep seems to be coming from somewhere above the filler plug on the side, which has puzzled me. It's not a major leak just a dampness that seeps slowly down the side and hardly causes a drip to form. I contacted Dave Ashcroft who supplied the box a few years ago and he reckons its most likely the O-ring on the top horizontal shaft - item 12 below. Dave said: item 19 is an O ring which should seal this shaft in the housing, often this doesn’t seal and the oil passes it and fills the front cavity under the FTC7155 housing,you can remove the top housing and fit a new O ring but the hole in the housing may be worn so the new O ring may not seal 100%,the top housing will have to be removed to be stripped, I have an old LT77 lying in the garage so I thought I'd have a go at removing the top just as a practice before getting in about the one in my van but I cant get the housing to lift - the bolts are out but there is something underneath retaining the housing - the part I'm referring to is the piece to the left in the above image from Shaun's excellent original post. The area to the left, beside the twin green wire and above the pink gasket. It's obviously not as straightforwards as I thought! What else must I disconnect to release this top housing? Quote Link to comment Share on other sites More sharing options...
Jocklandjohn Posted June 5, 2016 Share Posted June 5, 2016 I've got a leak on the side of my gearbox - it's a later model LT77 (which I think is LT77s). The weep seems to be coming from somewhere above the filler plug on the side, which has puzzled me. It's not a major leak just a dampness that seeps slowly down the side and hardly causes a drip to form. I contacted Dave Ashcroft who supplied the box a few years ago and he reckons its most likely the O-ring on the top horizontal shaft - item 12 below. Dave said: item 19 is an O ring which should seal this shaft in the housing, often this doesn’t seal and the oil passes it and fills the front cavity under the FTC7155 housing,you can remove the top housing and fit a new O ring but the hole in the housing may be worn so the new O ring may not seal 100%,the top housing will have to be removed to be stripped, I have an old LT77 lying in the garage so I thought I'd have a go at removing the top just as a practice before getting in about the one in my van but I cant get the housing to lift - the bolts are out but there is something underneath retaining the housing - the part I'm referring to is the piece to the left in the above image. The area to the left, beside the twin green wire and above the pink gasket. It's obviously not as straightforwards as I thought! What else must I disconnect to release this top housing? Quote Link to comment Share on other sites More sharing options...
AnthonyHRobinson Posted May 20, 2020 Share Posted May 20, 2020 Hi you say the nut needed to make up the press tool is an odd size at 18mm which you wind onto the output shaft, can you let me know on the size and pitch of nut needed please. I've tried all in my random selection and none fit. Many thanks Quote Link to comment Share on other sites More sharing options...
paroak Posted February 17, 2021 Share Posted February 17, 2021 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. Quote Link to comment Share on other sites More sharing options...
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