LT95 rebuild for beginners

**steveG** · 17th February 2011, 09:53 PM

The things left to do at this point are to fit:
- diff lock collar
- front output housing
- diff lock actuator
- bell housing
- clutch release arm/pushrod/bearing

They are all pretty straightforward assembly tasks.

Only a couple of comments from my experience..

Sucking with your mouth is enough to engage/disengage the diff lock, so its a worthwhile test to do at this stage to make sure its working OK. If it doesn't engage by itself after a decent suck you might have to rotate one of the output shafts slightly to allow the locking collar to engage.
Test the diff lock switch is working correctly while you're at it (should be a circuit between the 2 pins with the diff lock engaged, and open circuit when disengaged)

As well as the clutch release arm and bearing, don't forget to fit the pushrod before refitting the box to the engine. Its a PITA to try and fit once its back in the car - but IS possible

The bell housing needs some sealant around the 3 selector arm holes at the top of the housing.

BTW - the rubber washer that goes on top of the gear lever ball (red part in photo below) - is it available as a separate part or do you need to fabricate one?
Looks like someone has just made this one up in the past.
If you have to make one - whats the best material type?

Steve

**Blknight.aus** · 18th February 2011, 07:50 AM

yep they can be had. or you can template one up out of any oil stabilised rubber of suitable thickness.

**steveG** · 18th February 2011, 09:09 AM

Originally Posted by Blknight.aus

yep they can be had. or you can template one up out of any oil stabilised rubber of suitable thickness.

Anyone know a P/N. Can't find it listed separately in the parts lists I have.

Steve

**Bearman** · 18th February 2011, 06:17 PM

Originally Posted by steveG

Anyone know a P/N. Can't find it listed separately in the parts lists I have.

Steve

I am away from home atm but will dig out the p/n when I get home tomorrow arvo. Most parts manuals don't list it.

**Bearman** · 19th February 2011, 12:56 PM

Originally Posted by steveG

Anyone know a P/N. Can't find it listed separately in the parts lists I have.

Steve

The part number is R622387
The rubber boot that fits over the gear lever and seals around the top of the box is 90576646

**steveG** · 19th February 2011, 12:59 PM

Awesome - thanks Brian.

Steve

**rrc80** · 23rd February 2012, 12:01 AM

hey guys, i know its a old thread but where did you's get the books/manuals on how to rebuild them?

Cheers, Andy

**steveG** · 23rd February 2012, 09:30 AM

Originally Posted by rrc80

hey guys, i know its a old thread but where did you's get the books/manuals on how to rebuild them?

Cheers, Andy

The LR Rave manuals have the gearbox info in them. LT95 info is in both the RRC manual and the early 110 ones. Buy a CD with them on from the AULRO shop at the top of the page.

**Landie333** · 27th February 2012, 08:10 PM

I'm loving this thread. It is helping me out alot in my rebuild (it's current;y sitting in bits on the bench, while I clean all the parts and get seals/bearings) of my LT95, as I'm a newb to the box and to Landys. Thankyou to all.

I have a few questions. What manuals are best inregards to rebuilding the gearbox/TC? I saw in earlier posts some references to manuals, but no real names. Also who are the best suppliers to purchase them from? I'm still trying to build up my Land Rover supplier contacts.

Many thanks.

**steveG** · 27th February 2012, 10:06 PM

Easiest way is to buy one or both of these CD's from the Aulro shop:

Dave's Interesting Things - RRMAN70-85

Dave's Interesting Things - LANDYCD

First one is only Rangie, but has the parts manual, and the second one also has defender, disco and more, but no parts manual.

Steve

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