Introduction Gearboxes We supply fully reconditioned manual gearboxes and transfer boxes from stock. This section also includes a range of gearbox Service Kits, comprising the most commonly needed parts - synchro rings, bearings, oil seals & gaskets - for a straightforward gearbox overhaul. We have avoided listing every single component associated with manual gearboxes, because there is a point beyond which DIY gearbox repair is no longer cost-effective, and replacement with an off-the-shelf reconditioned unit would probably be cheaper. Also, since gearboxes are large and fairly complex, replacement may prove simpler in the long run. Nevertheless, if there is an item which you require that is not listed, please contact our sales department. Gearbox Identification To identify the type of gearbox/transfer box fitted to your Range Rover, refer to the serial number stamped on the unit itself: 4 speed. Only one type of 4-speed manual gearbox is fitted - the LT95 unit - with integral transfer box. 5 speed. The 5-sp gearbox, introduced in 1983, is the LT77 unit, with a serial number which begins 52A.(The serial number of 5-sp boxes is stamped on the main body of the unit, on the lower right-hand side. The number begins with the identification prefix, according to the engine type, followed by the actual serial number and finally, a suffix letter; either D, E, F, G or H). With the introduction of diesel engines in April 1986, serial numbers for the LT77 5-sp begin 53A for V8 and 54A for diesel. In December 1991, the LT77 5-sp was replaced by the LT77S. Gearbox numbers are still 53A for V8 and 54A for VM diesel, but with the addition of 55A for Tdi engines. The LT77S 5-sp was replaced in March 1994 by the R380 5-sp box. As before, identification numbers begin 53A and 55A for V8 and Tdi respectively, but now with a suffix 'J'. All 5-sp gearboxes have separate transfer boxes.

Manual Gearbox Units

Gearbox assembly;
LT95 (4 speed) -
Includes transfer box.
New - (1) - STC280E
Recon - (1) - STC280R

LT77 5 speed (1983 to Nov 1991) -
Less transfer box.
V8 models
Factory recon - (1) - FRC6197E
Recon - (1) - FRC6197R
Diesel models
Factory recon - (1) - FRC8572
Recon - (1) - FRC8572R

LT77 5 speed (Dec 1991 to Apr 1994) -
Less transfer box.
V8 models
Recon - (1) - RA1098R
Diesel models.
Recon - (1) - RA1099R

R380 5 speed (Mar 1994 onwards) -
V8 models
Recon - (1) - RA1100R
Diesel models
Recon - (1) - RA1101R

Service Kits

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Service kits include the parts normally required to recondition a high mileage gearbox - (Main box) bearings, synchro rings, oil pump gears, oil seals, gaskets & (transfer box) rear oil seal.

Service kit;
LT95 4 speed - (1) - RA1250
LT77 5 speed -
1983 to gearbox no. 0132346D - (1) - RA1251
From gearbox no. 0132347D to gearbox suffix F - (1) - RA1252
Suffix F & G - (1) - RA1253
Suffix H - (1) - RA1254

LT77S 5 speed - (1) - RA1255
Suffix J 1992 onwards.

R380 5 speed - (1) - RA1256
1994 onwards.

Gaskets & Oil Seals

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Gasket set (Manual gearbox);
LT95 (4 speed) - (1) - 606754
LT77 & LT77S (5 speed) - (1) - RTC6797

Oil seal (Front);
LT95 (4 speed) - (1) - 571059
LT77 & LT77S (5 speed) - (1) - UKC1060
R380 (5 speed) - (1) - UKC1060

Oil seal (Rear);
LT95 (4 speed) - (1) - 90622240
Rear of transfer case.
LT77 & LT7S (5 speed) - (1) - ICV100000
R380 (5 speed) - (1) - FTC2383

Gearlever Housing Kit

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Gearlever housing kits contain parts which are prone to wear, resulting in vague gear selection.

Gearlever housing kit;
LT95 (4 speed) - (1) - RA1257
Includes gear lever retainer & seal, grub screw, upper & lower gaiters and retainer screws.
LT77 (5 speed) -
1983 to 1986 - (1) - RA1258
1 piece lever. Includes gear lever retaining nut & washer, lever spring, roll pin, 2 x lowerpins, lever housing gaskets and plunger & spring.
1986 onwards - (1) - RA1259
2 piece lever. Includes spherical nylon bush, oil seals, gaskets, lever springs, 2 x lower lever pins and plungers & springs.

R380 (5 speed) - (1) - RA1260
2 piece lever. Includes lever springs, lower pins, spherical bush and oil seals.

Reverse Light Switch

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Switch (Reverse light);
LT95 4 speed - (1) - BAU1074A
Located in top of gearbox.
LT77 & LT77S 5 speed - (1) - PRC2911
Located in lever housing.
R380 5 speed - (1) - CDU51
Located in rear extension.

Washer (Switch);
LT95 4 speed - (1) - FRC5674
R380 5 speed - (1) - 232042

Locknut (Switch) - (1) - 22A1613
LT77 & LT77S.

Vacuum Actuator - Diff Lock - LT95 (Manual)

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Vacuum actuator - (1) - RTC4512
Washer (Actuator) - (1) - FRC5674

Gearbox Oil

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Unipart 20W/50 (1 litre) - (ar) - GGL614
Unipart EP90 (0.5 litre) - (ar) - GGL190

Unipart ATF;
0.5 litre - (ar) - GGL175
5 litre - (ar) - GGL505

Lubricants & Capacities
Main Gearbox	Lubricant	Capacity
LT95 (4 speed)	20W/50	2.6 litres (4.5 pints)
LT77 & LT77S (5 speed)	ATF	2.2 litres (3.9 pints)
R380 (5 speed)	ATF	2.7 litres (4.7 pints)
3 Speed Auto (Chrysler)	ATF	8.5 litres (15 pints)
4 Speed Auto (ZF)	ATF	9.1 litres (16 pints)
Transfer Gearbox
LT95	20W/50	3.1 litres (5.5 pints)
LT230R/T	EP90	2.8 litres (4.9 pints)
Borg Warner	ATF	2.4 litres (4.2 pints)

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Fri, 25 Jul 2008