Rover's Vikingship Overhaul of the LT 77 Gearbox
part five
Rover's Vikingship












Important!!

This part of site is an attempt to organize and add to the web resources for the Rover SD1 to form a cohesive and easily usable guide for those of us without easy access to expert repair and/or advice. It is not offered in any way as a definitive source and we take no responsibility for any errors that may exist.
the webmaster Rene Winters.


Now the remote control housing, remove the bottom cover and examine the two nylon bushes for wear.
Position the connecting pin in the selector shaft bore and fit the nyloc nut.
Offer the housing to the gearbox assembly and manoeuvre the remote shaft to enable the g connecting pin to engage.
Fit the four bolts to retain the housing. The shorter bolts go in the side positions.


Reverse Baulk Plate

The first adjustment is to the reverse baulk plate. Select neutral and make sure the lever is in a vertical position. Release the locknuts and slacken the adjusting bolts until the baulk plate just contacts the backing plate then tighten the two bolts equally until they just start to move the baulk plate.
Now using a spring balance, connected to the top of the gear lever, measure the force required to move the lever to the reverse gate. Here we have fitted a nut to the lever to prevent the spring balance slipping when under tension. Adjust the two bolts to achieve the correct operating load; this is 13.5-16.0 kgf (30-35 lbf) but keep in mind, when the lever is in the neutral position, a minimum gap of 0.25mm (0.01 in) must be left between the upper face of the baulk plate and the lower edge of the gear lever bush.

1ST/2ND GATE STOP
Next, adjustment of the 1 st/2nd gate stop. Engage 1st gear and measure the gap between the gear lever and the edge of the baulk plate. It should be 0.25-1.25 mm (0.01 -0.05 in). The gap is adjusted by fitting shims behind the baulk plate spring carriers. After making an adjustment re-check the load required to over-come the baulk plate, as reverse is selected. When all readings are correct, fit the bottom cover.

Gear Lever Bias Spring

Now the gear lever bias spring, engage third gear and adjust the two bolts so that both spring legs are 0.5mm (0.02 in) clear of the cross-pin. Lightly pull the lever to the left, to take up any play, and adjust the right hand bolt downwards until the right hand spring leg contacts the cross-pin.
Repeat the procedure on the other side, holding the lever to the right; then select neutral and rock the lever across the gate.
The lever should return to the 3rd/4th gate when released. The two locknuts can then be tightened.

Reverse Light Switch
Finally, the reverse light switch, connect a battery and test lamp to the switch terminals.
Select reverse, release the locknut and rotate the switch until the light just comes on; then rotate the switch 180 in a clockwise direction and tighten the locknut.
To finish the rebuild, fit the bell housing, the clutch release bearing and support sleeve, the withdrawal lever and slipper pads and the pivot pin. The box can now be refitted to the car.
One final point, after filling the box with oil, fit a new fibre washer to the filler plug, and tighten the plug to the correct torque.


5 sp Gearbox part one
part two
part three
part four
Torque Wrench Settings

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