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Series 5 speed kits

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  • Technical

    Please note if you are fitting this kit the diameter indicated below must be the larger 108mm rather than the smaller 88mm version.

     

     

  • Installation

    Note- this conversion increases the length of the transmission by 102mm overall i.e. the engine mounts must move forward or the gearbox mounts back by this amount.

    LR77 Conversion Fitting notes

    You should have received:

    1 x conversion plate with brg housing, 4 dowels, brg outer and seal

    1 x input gear with brgs

    1 x PTO cover with brg outer

    1 x transfer case inspection plate

    1 x selector shaft cover plate

    1 x breather pipe and banjo bolt

    1 x high / low lever mounting bracket (angle iron 10“)

    8 x M10 x 30 cap heads (plate to LT 77)

    1 x M10 x 40 cap head (plate to LT 77 dowel)

    3 x M10 x 30 hex heads (transfer box to plate)

    3 x M10 plain washers (transfer box to plate, inside)

    3 x M10 spring washer (transfer box to plate, inside)

    5 x input gear shims, 0.05, 0.1, 0.2, 2 x 0.3mm

     

    1.  Pre assemble plate to transfer case, fit new gear and PTO cover plate,

    using a gasket. The preload on the input gear must be set using the shims supplied which sit between the rear PTO cover and the rear gear bearing outer, the gear should have ‘light drag’ ie not spinning freely and not pinched tight. Mark the transfer case along the top edge of the conversion plate. Check the side to ensure the cap head bolt used to bolt the plate to the LT 77, will fit. It may be necessary to trim the edge of the transfer case to clear the bolt head.

    2. Disassemble and fit the conversion plate to the LT 77 gearbox. For LT77 only cut the top off the transfer case lobe level with the top edge of the conversion plate, to clear the reverse light switch this is not necessary on R380. The rest of the assembly proceeds as normal.

    3. Check the plate fits on the LT 77 properly before bolting up.

    4. When assembling the transfer case to the LT 77 do not use a gasket, use RTV and also fill the vertical vent slot to prevent oil leaking out, the vent is now via an axle breather in the top cover plate.

    5. Because of the increased length of the LT 77 the H/L bracket will need a new support. Weld the angle iron supplied to the RH gearbox bracket as indicated in the sketch.

    6. When assembling the transfer case to the LT77 use EP90 oil on the spline, grease should not be used. The gear has been drilled to allow splash lubrication of the spline.

    7. This hole will need filling with sealant or similar: