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Mike.s

Member Since: 19 May 2015
Location: Weymouth
Posts: 30

LT77 Strange 5th Gear

Hi,

I `ve just fitted a replacement gearbox to my defender. To be fair, it is off unknown quantity, but i was told that it was removed froma running car and was working fine.

The problem is that, i`ve just fitted and put my gear selector back on (the whole gear shift and diff lock mechanism together by the 4 bolts on the rear of the gearbox).

I have no oil in the gearbox or transfer box yet, but thought i`d check the gear selection. The selector centres on 2/3 and I can select 1,2,3,4 and reverse, but 5th is no where to be seen. It just comes to a stop when trying to select it. I ve removed the selector unit and get the same result by selecting it manually without the linkage.

Now the strange thing is where you would expect a 6th gear (if there ever was one), i can select a gear there - ie. - if you pull back from 5th, you get a gear there.

The lt77 is an ex MOD recon unit if that helps.

What is going on? If i fill with oil, would that make any difference and also, if the engine was spun over would that make any difference. And was is the strange 6th gear!?

Cheers, MIke

7th Sep 2015 8:03pm

Mike.s

Member Since: 19 May 2015
Location: Weymouth
Posts: 30

I`ve just checked the serial numbers - my old gearbox is a 50A suffix G and the new box is a 51A MOD box.

Could the linkage on the 50A be different to the 51A?

I checked the old and new box - without the selector mechanism, 5th gear is definitley different on th etwo boxes. On the 50A box, the selector has to be pushed all the way over to the right, then forwards. On the 51A box, it has to be pushed all the way right, then backwards.

I did notice that the stick appears to have been welded at some point - i presume to be fixed as it may have snapped in the past, but maybe not?

Here`s pics of the selector mechanism on the new box -

Click image to enlarge

7th Sep 2015 9:15pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

1991 Defender 110 200 Tdi USW Arles Blue

I think your best bet would be to give Ashcroft Transmissions a ring tomorrow as they will know exactly what you need.

I have never known a LT77 to have a 5th gear as select right then down, only ever as right then forward.

Is this the one which has the much lower 1st gear? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

7th Sep 2015 9:24pm

Mike.s

Member Since: 19 May 2015
Location: Weymouth
Posts: 30

Yes - it should have a slightly lower 1st and 2nd.

I`m only presuming its 5th gear - i have no props connected at the moment and can`t drive it. Reverse is definitely in the right position - you can hear the distinctive clack when it selects. 1,2,3 and 4 all appear to be correct locations aswell.

7th Sep 2015 9:39pm

Mike.s

Member Since: 19 May 2015
Location: Weymouth
Posts: 30

I had a closer look in the light this morning and it looks like there is a collar which should slot into to the selector(?).

This is mine - the selector is pushed all the way over to the right. I tried to lightly push it back, but it felt pretty jammed and i didn`t want to break anything.

Click image to enlarge

You can see on this pic i found where it slots in. I have a pic from when i boiught it and mine looks aligned then, so it must have come out somehow and then attempting to select 5th has pushed the selector ring back and jammed it.

Click image to enlarge

Should it come back easily or can i rotate, the collar, etc and then pry it back with no damage?

Thanks, mike

8th Sep 2015 7:36am

Mike.s

Member Since: 19 May 2015
Location: Weymouth
Posts: 30

Just a quick update as i think i have hopefully sorted it.

I have no idea how the interlock cam disengaged from the selector, but i ended up carefully removing the circlip on the selector, then sliding the collar back. I could then push the selector back into position and re-engage the peg form the interlock.

Pushed the circlip back on and with the linkage back on, everything seems to be moving how it should be.

5th seems a little sticky/stiff, but hopefully with some oil in the gearbox, it will get a little freer

8th Sep 2015 6:19pm

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