Leaky LT77

[alexturner]

Hey guys,

I've had my LT77 rebuilt now - twice and it's still leaking. Leaking enough to empty the box every 3 months. Today I've dropped the box and intend on re-gasketing the unit as I don't trust the mechanic in Seven Hills who rebuilt the box.

Any advice to do something like this? I won't be touching the gears but it sounds like I'll need something to pull the oil seal collar. I've already got my hands on an LT77 gasket kit. From what it seems so far, it seems as if the box has been sealed with gasket goop.

[langy]

I've just finished playing with a broken lt77 - there are a couple of things to note about pulling it apart:
- Stick with gaskets. When I pulled mine apart, (circa 91) it had gaskets only. I suggest trying hylomar. ( Spray on). Hylomar does not change the gasket thickness and is good at sealing. I use it on head gaskets.
- however, you'll need to go thru checking the shim on both the main and layshaft. The lt77 relies on either zero preload or gap. After using gasket goo, going back to gaskets will change that.
- Unlike a R380, there is a circlip on the collar. It reasonably easy to remove, say, using bent circlip pliers or two small screwdrivers.
- The collar comes off fairly easy using a decent hydraulic puller with a bearing puller in the groove. ( A replacement collar is roughly $20 from LR dealers)
- The extension case comes off easy - it's oil seal ( If you want to replace it) is the same at the LT230 input seal.
- Watch the rear spool retainer when you remove the extension case - it can upset the gear change.
- Remember to remove the front spool retainer ( I forgot and broke mine)
- The middle plate and front section have locating pins .They take a bit of effort to separate
- Sit the gearbox vertical. When you pull the middle plate up the mainshaft should stay together. There will be a layshaft washer fall off, but that's it. If you pull it horizontal, it may disassemble.
- Leave the gear change alone if possible. It can lock up if you fiddle with it loose. (What a PITA it is to unlock it)
- A LT77 rebuild manual is very helpful - especially when things fall apart (quite literally)
- To get the collar back on, I used : 1 x M18 (coarse) ordinary (not nyloc) nut, 1x washer with 21mm (13/16) hole 45 mm dia, 1x 85mm long piece of heavy wall pipe ID 33mm OD 42mm, 8x washers ID 32 OD 57 3.5 thick. The collar winds on reasonably easy with the smaller washer and pipe to start, then two stages with 4 washers each. The collar finishes about 1mm proud of the case, at which point you reinstall the circlip. A little grease on the shaft o-ring helps before installing the collar.


Good luck

[isuzurover]

So - does spending money on your landy mean you have paid for the lights?

After the lights have been paid for, buy some RTV and use that instead of silicone.

Better still, buy an R380 and Ashcroft stumpy bellhousing kit (but only after you have paid for the lights).

[alexturner]

Haven't spent any yet, been relying on handouts from dad, but that'll all be settled this week