LT76 Gearbox Rebuilt

My apologies for not getting this post done earlier, I actually finished the gearbox about a month ago but havent found time to work on the blog. Anyway, following on from the last post, I made a list pf all the parts I needed, and placed an order from the UK. I used a new supplier for this order www.brit-car.co.uk ,  mainly because they had a better range of genuine parts than lrdirect.
I tried to use all genuine parts where possible (some items are just stupidly priced so I used Bearmach as a substitute) but I'd say it was 90% genuine. I sourced most of the bearings locally from SaecoWilson, but there were a few that worked out cheaper to get from the UK. For these I used Britpart 'G' suffix items, which are actually reputable brand bearings, just in a blue box, in this instance they were NTN bearings which are good quality.  Here is my total list of parts used

Part No.	Description	Qty
55714	primary pinion brg RLS12	1
6397	Brg Needle Roller Spigot main shaft front	1
RTC1957	Main Shaft snap ring	2
591364	Syncro ring 1st/2nd	2
RTC1979	Mainshaft peg	1
576734	Mainshaft bush	1
600603	Gearbox gasket kit	1
1645	mainshaft rear brg 6307	1
528701	layshaft front brg 6305	1
RTC1412	Layshaft rear brg - cyl. Roller CFL7A	1
521328	Inter Thrust Washer T Box	2
599869	Inter roller brg	2
217490	Output shaft brg rear T/Roller 14137A	1
90217512	Low Gear/Speedo Drive brg t/roller 28317	1
217325	Front output brg RLS10	1
272596	O Ring Selector Shaft forward gears	2
272597	O Ring Selector Shaft reverse	1
5852	sealing ring - indent springs	2
3649	selector spring forward gears	2
56102	selector spring reverse	1
211502	Oil seal speedo drive	1
217476	Rear Mainshaft Lock Tab S1 2 2A & 3	1
267828	o ring speedo drive	1
561197	intermediate shaft shim	2
532323	intermediate shaft o ring	1
591363	2nd gear	1
RTC1956	detent spring 3rd/4th synchro	3
9960	Circlip main shaft brg	1
528683	lock washer layshaft front brg	1
231116	Spring for reverse gate	2
TRS1013L	Range selector shaft seal	1
FRC1387	gear lever ball o ring	1
219723	Gear lever spring	1
236305	mainshaft rear oil seal	1
FRC1780G	Output seal	2
571059G	Front oil seal	1
561954	Reverse idler bush	1
608283	in/out mech 1st-2nd	1
591362	1st gear	1
556010	3rd gear	1
FRC1758	3rd/4th Synchro clutch	1
571218	Mainshaft distance sleeve	1

So in short, I replaced every seal, every gasket and every bearing. I could talk you through the entire process but all the info is out there on the web. Instead I'll list my sources of info:

• https://www.youtube.com/user/steamwally This guy has excellent videos and is obviously a good engineer.
• http://www.geoffslandroverblog.com/ As always, geoffs blog is super handy
• Series 3 Workshop Manual Pretty obvious but everything you need is in here, just not in sequential order so have a flick through first. (only thing I couldn't find in here was the torque for the main shaft nut, which I ended up taking from a Fairey Overdrive manual, and is 100 ft/lb.

I'll let the photos do the talking

 Bits and pieces repainted black

 Parts cleaned and ready for assembly

 Castings degreased 

 Genuine gears

 Ready to go

 New reverse idler bush fitted and machined to fit shaft. Thanks to my Dad, as I was off work and didn't have access to a lathe

 Reverse Idler fitted

 Box of bits from brit-car

 Setting end floats on the main shaft. This was quite time consuming, but all within spec eventually after taking to the bush with some fine emery

 2nd & 3rd gears fitted up. Use a new snap ring for this (get 2, as you have to take it on and off a few times while setting the end floats, and they stretch.

 Genuine synchro (baulk) rings 

 Fitted, I had to use some very fine sandpaper on the gear cone to polish it slightly , as the synchro rings were 'screwing' onto the fine machining marks, effectively getting 'stuck' to the gear. 

 New 1st gear bush 

 All new except 3rd gear and the main shaft

 New springs in the 3rd/4th synchro clutch

 Main shaft bearing, taken from it's original packaging, probably older than the Land Rover!

 New oil seal fitted rear of main shaft 

 Layshaft rear cylindrical roller bearing 

Outer race of layshaft bearing fitted to the main gear case. Contrary to what you may be told, you don't need to freeze or heat all the interference fits. A correctly sized mandrel to press on either the inner or outer race (depending on situation) and a decent hammer was all I needed.

 Main shaft & Layshaft  in the box

 Primary pinion shaft and bearings fitted to the bell housing 

 Bellhousing fitted. This is a fiddle and requires 3 hands to align the first layshaft gear with the primary pinion, while also aligning the castings

New seals fitted to selector shafts. They are genuine LR seals, but they don't look like they'll keep much oil in. I guess that makes it a 'genuine' gearbox if its leaking

 Torquing main shaft nut, to 100 ft/lb with the CORRECT TOOL! No cold chisels in sight..

 Main casing finished (lever fitted just to test that all gears selected) 

 Outer race of taper roller bearing on it's way into the transfer case

 Low & Hi gear fitted

 1x Timken & 1x NTN (britpart 'G' Suffix) Taper roller bearings

 Setting bearing pre-load of output shaft with a spring scale (0.9 - 1.8 kg) This is adjusted by adding or removing speedo housing shims 

 Intermediate gear with new thrust washers, o ring and needle roller bearings. I bought new Santana shims incase the endfloat was excessive but the new thrust washers provided a nice fit.

 Front output bearing fitted, flange w/ seal about to go on

 Lo/Hi range and 4WD selector shafts fitted

 Front output housing fitted to transfer case

Mating up to the main gearcase

 View from the bottom of the transfer case

 Transmission brake parts painted up

 Hasn't looked this good since 1973

 New shoes and springs

 Drum fitted. The nylock nuts are BSF thread. 99% of the gearbox is BSF/BSW so invest in a whitworth socket & spanner set 

Gearbox back in it's rightful place!

I've got 2 new propshafts to go on now, and then the plan is to get the brakes fitted , with all new brake pipes etc.