defenderNorthEast
Member
Hi All,
I've had the LT77s 56A Suffix H rebuilt twice now by a local gearbox specialist. First time had new mainshaft, 1 through 5 baulk ring triples, 1/2 thrust washers and gaskets and seals.
Then when i finally finished the rebuild and had the defender on the road it kept popping out of first gear and second didn't feel much better. So back to the specialists to see what was wrong, they informed me first gear was worn and needed replacing. Annoyingly gearbox back out and off for the work again, this time new first and second gear, new syncro STC8577 (Got lucky with this part as all of the major suppliers have it on back order and one shop in Ireland happened to have had it in stock since 2012), not sure on the make it wasn't a blue box part but the sticker said OEM part, and then new seals and gaskets.
Box back in and now first gear doesn't pop out but sometimes i have trouble getting it into gear at a stand still, its like pushing a brick wall.
I might remove the 3mm slave spacer as the clutch engage ment is low to the floor, i originally put it in as with a new britpart master the travel was still very high, but i don't really see any connection to the gearbox problem.
I've had the LT77s 56A Suffix H rebuilt twice now by a local gearbox specialist. First time had new mainshaft, 1 through 5 baulk ring triples, 1/2 thrust washers and gaskets and seals.
Then when i finally finished the rebuild and had the defender on the road it kept popping out of first gear and second didn't feel much better. So back to the specialists to see what was wrong, they informed me first gear was worn and needed replacing. Annoyingly gearbox back out and off for the work again, this time new first and second gear, new syncro STC8577 (Got lucky with this part as all of the major suppliers have it on back order and one shop in Ireland happened to have had it in stock since 2012), not sure on the make it wasn't a blue box part but the sticker said OEM part, and then new seals and gaskets.
Box back in and now first gear doesn't pop out but sometimes i have trouble getting it into gear at a stand still, its like pushing a brick wall.
- Clutch (new with heavy duty release bearing) seems to fully disengage as the tell tale LT77 rattle goes away and all other gears select fine
- New master (LOF upgraded one), slave (orientated bleed nipple at top) with 3mm spacer and rubber pipe
- Bled on an incline no spongy feel, doubt there is any air in the system, although travel is at the bottom 3 inches of the pedal
- ATF gearbox oil and 0.5L of Lucas heavy duty oil stabliser
- All the other gears select fine (1 to 2 and 3 to 2 are fine) and some times it will go into first no problem
- If i select 2nd and then get it rolling i can then get it into first
- 1.5mm shims on the 1/2 bias, have changed the amount of shims around but made no difference
- I can roll the defender along and stop and it will go in 1st, i can then move it a meter or 2 and it won't
I might remove the 3mm slave spacer as the clutch engage ment is low to the floor, i originally put it in as with a new britpart master the travel was still very high, but i don't really see any connection to the gearbox problem.
Last edited:
