Manual Transmission/Transaxle: Service and Repair
REMOVE LT77S MANUAL GEARBOX AND LT230 TRANSFER BOX
WARNING: Where the use of a transmission hoist is necessary, it is absolutely essential to follow the manufacturers' instructions to ensure safe and effective use of the equipment.
1. Install the vehicle on a ramp.
2. Disconnect the battery.
3. Remove the gear lever knob.
4. Remove the transfer and differential lock knob.
5. Remove the gear lever cover.
6. Remove the 10 mm Nyloc nut and plain washer. Mark the gear lever spline setting and detach the gear lever and gaiter from the splined lower gear lever.
7. Select high range to prevent the transfer gearbox selector lever fouling the tunnel when removing the gearbox.
8. Remove the bonnet.
9. Remove the nuts and bolts retaining the fan cowl to the engine and move the cowling forward, clear of the engine.
10. Release the transmission breather pipes, speedometer cable, and starter motor harness from dips at rear of the engine.
11. Release the air filter hose at filter.
12. Raise the ramp.
13. Remove the eight nuts and bolts securing the chassis cross member arid using a suitable means of spreading the chassis, remove the cross member.
14. Place a suitable container under the transmission, remove the three drain plugs, allow the oil to drain and refit the plugs. Clean filter on the extension housing plug before refitting.
15. Remove the intermediate exhaust pipe and silencer section as follows:
(a) Release the connection to the front pipe at the flange.
(b) Release the connection to the rear section at the flange immediately behind the silencer.
(c) Remove the 'U' bolt retaining the pipe to the bracket attached to the transfer box.
16. Mark the flanges for reassembly and disconnect the front propeller shaft from the transfer box.
17. Similarly, disconnect the rear propeller shaft.
18. Disconnect the speedometer cable from the rear of the transfer box.
19. Disconnect the handbrake inner cable by removing the split pin and clevis pin.
20. Slacken the retaining nuts and release the handbrake outer cable from the bracket.
21. Remove the two bolts and withdraw the dutch slave cylinder from the bell housing.
22. Manufacture a cradle to the dimensions given in the drawing and attach it to a transmission hoist. To achieve balance of the transmission unit when mounted on the transmission hoist, it is essential that point A is situated over the centre of the lifting hoist ram. Drill fixing holes B to suit hoist table. Secure the transmission unit to the lifting bracket at point C. by means of the lower bolts retaining the transfer gearbox rear cover.
23. Remove the bottom two bolts from the transfer box rear cover and use them to attach the rear end of the cradle to the transfer box. Ensure that the tube in the centre of the cradle locates over the extension housing drain plug.
24. Raise the hoist just enough to take the weight of the transmission.
25. Remove the three nuts and bolts securing the transfer box L H and R H mounting brackets to the chassis.
26. Remove the nuts retaining the brackets to the mounting rubbers and remove the brackets.
27. Lower the hoist sufficiently to allow the transfer lever to clear the transmission tunnel aperture.
28. Disconnect the four-wheel drive indicator electrical lead (bullet connection).
29. Remove the deat retaining the reverse light switch wires from the R H side of the gearbox.
30. Disconnect the wire from the reverse light switch situated at the top rear of the selector housing and move the harness away from the transmission.
31. Support the engine under the sump with a jack, placing timber between the lack pad arid sump.
32. Remove the eleven bell housing nuts.
33. Withdraw the transmission whilst ensuring all connections to the engine and chassis are released.
Separating the transfer box from gearbox
34. Remove the transmission assembly from the hoist and cradle and install it safely on a bench.
35. Remove the four bolts securing the transfer gear change housing to the remote gear change housing.
36. Remove the two bolts retaining the cross shaft lever pivot bracket to the extension housing.
37. Release the connecting link from the differential lock lever.
36. Disconnect the pivot arm from the high/low shaft.
39. Remove the lower locknut from the high/low operating rod.
40. Remove the breather pipes.
41. Hoist the transfer box into position ensuring that the loose upper dowel is fitted. Assemble to the main gearbox extension housing and secure with the four bolts and two nuts.
42. Reverse instructions 37 to 40.
Fitting main gearbox and transfer box to engine
43. Fit the cradle to the tr5nsmission hoist and the transmission to the cradle as described in instruction 23. Smear Hylomar on bell housing face mating with engine.
44. locate the gear lever temporarily and select any gear in the main gearbox to facilitate entry of the primary shaft.
45. Position and raise hoist and fit the transmission to the engine whilst keeping wires and pipes clear to prevent trapping.
46. Secure the transmission to the engine with the eleven nuts, noting that the top R H nut holds a clip for the speedometer cable.
47. Position the reverse light wires to the R H side of the main gearbox and secure with a cleat to the breather pipes.
48. Connect the reverse light wire to the switch at the top rear of the selector housing.
49. Connect the differential lock indicator wires (bullet connection).
50. Raise the transmission to line~up with the engine and ensure that the transfer lever clears the tunnel aperture.
51. Fit the transfer box L H and R H mounting brackets but only partially tighten the securing nuts and bolts.
52. Loosely ft the rubber mounting nuts and lower the transmission onto the mountings. Fully tighten all the securing nuts and bolts.
53. Remove the supporting jack from under the engine sump.
54. Remove the two bolts securing the cradle to the transfer box and remove the cradle and hoist.
55. Refit the two bolts using Loctite 290 on the threads and note that the L H bolt holds a clip for the speedometer cable.
56. Fit the slave cylinder using Hylosil on the gasket and tighten the two bolts evenly to 22 to 28 Nm.
57. Fit the handbrake cable using a new split pin to secure the clevis pin. Grease the clevis and tighten the outer cable lock nuts.
58. Connect the speedometer cable.
59. Check that the three drain plugs are tight and remove the main gearbox and transfer box filler level plugs. Fill the main gearbox with a recommended oil 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 a recommended oil until it runs out of the filler hole. Apply Hylosil to the threads and fit the plug and wipe away any surplus oil.
60. Line up the marks and fit the front and rear propeller shafts to the transfer box.
61. Fit the exhaust system, and evenly tighten the flange nuts and bolts. Fit the "U" bolt and secure to the bracket.
62. Expand the chassis side members, fit the cross member and secure with the eight nuts and bolts (four each side).
63. Fit the heater pipe damp.
64. Clip the breather pipes, speedometer cable and starter motor harness to rear of engine.
65. Fit the fan cowl.
66. Fit the bonnet.
67. 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.
68. Fit the cover to both gear levers and the knobs.