LT77 stuck in 4th gear - Defender Source
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  #1  
Old November 3rd, 2013, 09:22 PM
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LT77 stuck in 4th gear

One thing after another...

On the way back from Dave's place to pick up a new fuel filler cap (thanks Dave), my truck was doing fine until a quarter mile from home, when I tried to shift out of 4th. It would not shift out of 4th.

The clutch is not the problem, as it works fine (when I push the clutch in and rev, the engine revs freely).

The LT230 is working fine. I got home using a combination of 4th gear hi and 4th gear lo. The truck is currently parked safely, but I can't reverse out of the parking spot, as it is unable to go into reverse.

I have no interest in forcing the selector out of 4th, as I don't want to ruin anything (that isn't already ruined.)

Does anyone have an idea of what is going on? Is there a fix short of disassembling the LT77?

My plan is to start with trans cover removal, then to remove the top of the selector housing and make sure everything is ok in there.
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  #2  
Old November 3rd, 2013, 09:30 PM
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Quote:
Originally Posted by sonoronos View Post
One thing after another...

On the way back from Dave's place to pick up a new fuel filler cap (thanks Dave), my truck was doing fine until a quarter mile from home, when I tried to shift out of 4th. It would not shift out of 4th.

The clutch is not the problem, as it works fine (when I push the clutch in and rev, the engine revs freely).

The LT230 is working fine. I got home using a combination of 4th gear hi and 4th gear lo. The truck is currently parked safely, but I can't reverse out of the parking spot, as it is unable to go into reverse.

I have no interest in forcing the selector out of 4th, as I don't want to ruin anything (that isn't already ruined.)

Does anyone have an idea of what is going on? Is there a fix short of disassembling the LT77?

My plan is to start with trans cover removal, then to remove the top of the selector housing and make sure everything is ok in there.
4th is 1:1 (direct drive) so it is on a seperate shaft or something than the rest of the tranny, so that is why only 4th works, the problem lies within the tranny itself, im sure someone can shed more light on the situation, IIRC Ini88 had a similar problem in his defender.
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  #3  
Old November 4th, 2013, 07:11 AM
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Stuck in 4th is not common but can happen to these boxes. The solution is a rebuild
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  #4  
Old November 4th, 2013, 07:39 AM
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arrrrgh
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  #5  
Old November 4th, 2013, 02:16 PM
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arrrrgh
Google your problem, most 5 speeds have 4th as direct drive, so you will better understand the issues as a tranny being stuck in direct drive is generally a similar/same problem no matter what trans it is.
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  #6  
Old November 4th, 2013, 03:14 PM
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Thanks John,

Many of the posts give me hope that something is jammed up in my shifter column.

*fingers crossed*

I'll report back once the top cover is off.
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  #7  
Old November 4th, 2013, 04:00 PM
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Once you have it open I suggest emailing Dave Ashcroft. He's awesome with help.
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  #8  
Old December 4th, 2013, 10:12 PM
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Well, so I finally had some time to work on the gearbox.

The first thing I did was remove the drain plug and check the oil. My worst fear was that there was no MTL left in the transmission.

A 32mm wrench removed the LT77 drain plug.

What came out was a full transmission's worth of Redline MTL, along with a copious amount of finely powdered silver metal in suspension. Anyone know what this means? My guess is that is finely ground up synchro brass.

The magnetic drain plug was then checked for large particles. Fortunately, none were found. There is some fine swarf, but nothing that appears to me to indicate destruction of the gearbox.

Next, I removed the 4 bolts from the remote, the two connections to the LT230, and the LT77 shift lever. Unfortunately, this is where I stopped, as the seatbox fouls the top of the remote assembly. I will next have to lift the seatbox slightly to remove the remote assembly from the top of the gearbox.

It is clear, however, that the motion of the shifter is free at the remote, meaning that the "stuck" portion of the gearbox is within the gearbox.

If anyone has any comments/observations, please let me know.
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  #9  
Old December 4th, 2013, 11:10 PM
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http://forums.lr4x4.com/index.php?showtopic=72267

See the post from the expert (Ashcroft).
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  #10  
Old December 4th, 2013, 11:18 PM
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Thanks Ron. I have seen that post and I am concerned about that as well. A worn shift fork from a hyper-extended synchrohub would explain the copious metal powder.
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  #11  
Old December 4th, 2013, 11:50 PM
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Hi, my name is Capitan Obvious…need to re-build it, I have a core you can use if your need one...
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  #12  
Old December 5th, 2013, 12:04 AM
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Thanks Captain Obvious, good to hear from you as your input is often overlooked

Have you ever done a rebuild yourself, mongosd2? Is it particularly difficult given the right tools?
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  #13  
Old December 5th, 2013, 12:21 AM
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nope…I scored a re-built one…The re-build is pretty straight forward, and really just need a press (from what I was told by one of the diesel/mechanic guru's that I know)…
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Old December 5th, 2013, 01:08 AM
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Quote:
Originally Posted by mongosd2 View Post
nope…I scored a re-built one…The re-build is pretty straight forward, and really just need a press (from what I was told by one of the diesel/mechanic guru's that I know)…
Never did an LT77, but the R380 was not too hard. The only issue was getting a socket for the giant nut. The rest was done with a press and gear pullers in Ron good fashion.
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  #15  
Old December 5th, 2013, 09:59 PM
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Originally Posted by mongosd2 View Post
Hi, my name is Capitan Obvious…need to re-build it, I have a core you can use if your need one...
lmao. Frank you are priceless
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