Re: P6 project: BW35 to LT77 manual box swap: the verdict

Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

The pump is at the rear in the alloy housing section. You will need a puller to remove one of the gears
before being able to strip the main part of the box. The cluster comes out pretty much as a unit, but
be careful of shims on the ends of the layshaft as well as detent balls and springs etc.
It is a long time since I stripped my box, so the grey matter has lost some of it's stored info.

The input bearing is the weak point in this box, so you would do well to replace it. I think there is a
modification/upgrade that can be done, but I don't know the specifics of it. I never looked at mine before
slapping it in and it continued eating itself from the SD1 it came from and was done for in about 3 thousand km's.
The pump kit is available in UK so no fuss there.

As for oil, I don't know for sure. I was given different opinions, dependant on the weather and the alignment of
the planets, apparently. I know someone who had a V8 Land Rover and he used ATF, I was told to use ATF, EP90
and even engine oil...... :? :? :roll:

It completely transformed my car and is in my opinion well worthwhile doing. You will also need the pedal box and
master cylinder off a donor car and some plumbing is called for.

Have fun!
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Damian,

There should be no play in the input shaft. It has to be fitted with small preload. If you only change seals there is no need to open the box. You need to use ATF oil and no engineoil or EP oil

peter
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Damian!

I rebuild 2 LT77 and i bought the parts from Ashcroft transmissions. good quality bearings (Timken) at decent prices. They rebuild a lotof these boxes
Peter
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Hi guys, sorry delay in reply, All is going well so far, will gt some progress pics uploaded, One question if anyone has an answer:

I'm using a new SD1 clutch slave cylinder/pushrod, new SD1 pivot arm, release bearing and AP clutch kit for the SD1. (the engine block is the SD1 unit that came with the gearbox)

I need to know what the correct union size is for the SD1 Slave/cylinder fliud feed pipe as its metric and a bigger diameter then the union from the 3500's Master clutch cylinder that I'm using.

Any ideas if this makes sense! I'll need to get one made up, at a guess it'll only be about say 2ft long.

I've mounted the clutch master cylinder next to the brake master cylinder but turned the mounting plate around 180° so its away from the exhaust manifold, this is tried and tested by a friend on his P6 and works very will indeed.

Thanks & regards Damian
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

I replaced this pipe and the black hose with a SS braided hose on my MGB with Sd1 and LT77

Peter
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Hi Damian

In answer to your question regarding oil for the LT77, I did a lot of reading up on this when I first got Sparky, as changing gear was like stirring a saucepan of potatoes.

I opted for Redline MTL which has transformed the gearchange into areal slick shifter, even when cold.

http://www.ebay.co.uk/itm/Red-Line-MTL- ... 565ebfa85b

Richard
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Thanks for the info guys, Rich, how much does the g/box hold in litres? I know Im being lazy in asking but why not LOL, thanks for the ebay link, will get me some of that.
Sorted the fluid feed pipe situation, ordered 1x M12 thread with 3/16 diameter hole for the SD1 slave cylinder and 1x 7/16 union with same size for the master cylinder with a length of new pipe.
Anyway some pics, clean & painted floor plan, red oxide, Upol stone chip & tractol chassis paint over the top.

new clutch plate/pressure fitted, AP performance version, 30% stronger, new release bearing too, bargin off ebay.
2200 TC pedal box fitted, cut hole in the mounting plate then refitted 180 degrees to move the cylinders away from the exhaust manifold, will make a bracket to refit the heat shield. Started to do the g/box, cleaned the bell housing, replaced front input shaft seal, will do the rear next as soon as I can figure out how to jam the drive shaft flange to undo the bolt!, next will be to clean up the remote, fit new mounting rubbers, regrease linkage and put it all back together.
one bolted back on the engine I can then raise to the correct height and sort out the rear mounting.




 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

DamianZ28 said:
Thanks for the info guys, Rich, how much does the g/box hold in litres?

erm... from memory (my memory isn't good) it's 1.6L or thereabouts. You fill it with the gearbox level, to the bottom of the filler hole. If it starts running out, it's full. I know I bought two of the 946ml bottles and used slightly over 1 1/2 of them.

Richard
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Many Thanks Rich :D
One last silly question where is the drain plug anf the filler plug on this blessed thing? I can see various plugs but not sure which is what :oops:
Cheers Damian
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

DamianZ28 said:
Many Thanks Rich :D
One last silly question where is the drain plug anf the filler plug on this blessed thing? I can see various plugs but not sure which is what :oops:
Cheers Damian

Oil filler should be the hex-head plug on the alloy tail housing underneath the Leyland logo on the left hand side

sd1mangbox1_zps4b61d0d8.jpg


Oil drain is the hex-plug on the steel casing on the bottom right hand side

sd1mangbox_zps1c652bb0.jpg
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

DamianZ28 said:
Hi Simon,

Thanks for that!

Cheers Damian

No problem, I used to have one like that that I moved along years ago. I'm guessing it's quite an early box as it doesn't have the boss on the side by the drain plug with the serial number stamped in, and the others I have the oil filler is a taper plug on the opposite side in the steel casing.
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Quick update, Box fitted with cleaned bellhousing, new input/output shaft seals, new release bearing, new release arm and pushrod with clip. remote has new rubber mounts, cleaned & regreased
Have got he box bolted to engine and have modified the SD1 rear mounting to fit the old P6 auto box mountings welded to the inside of the trans tunnel.
Replace the UJ's on the propshaft, refit the exhaust, check the clearance on the slave cylinder as it may be very close to the O/S pipe, need to fit the slave cylinder first.
Bleeds brakes & clutch, slightly enlarge the hole so I can get all gears without any fouling of the gear lever, I can use the SD1 rubber cover and also the top gear lever cover which with a bit of modification will fit inside the auto plastic consol.
So progress is good, been about three months since I started but no rush for this, not keen on driving it in this weather, especially when the roads are salted.
Cheers Damian.


 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

SD1bellhousing_zps68a1f6ed.jpg


Do the arms come with that reinforcement over the pivot ball socket nowadays? I suppose it will take longer to wear through that....
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Hi Harvey, Yes the release arm came the reinforced bar welded to it for extra strength, I bought that, the push rod, clip, and the two holders for the pins on the release arm that sits on the releaser bearing housing from Mark Gray parts, very good service. cheers Damian
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

DamianZ28 said:
Replace the UJ's on the propshaft, refit the exhaust, check the clearance on the slave cylinder as it may be very close to the O/S pipe, need to fit the slave cylinder first.

Hi,

Yes it does get rather close, see pic. I just buffed the cylinder down a tad and turned it through 180 Degrees, seems to have worked just fine.

Tim
 

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Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Merry Christmas everybody!!! :D I hope Santa bought you all the Rover spares you asked for in your christmas list!

Thanks for the pics Tim, helpful tip, you did kindly send me a great link a while ago with pics of mounting the master cylinder in the same location as the 3500s.

Right better go before the other half see's me on the line...cheers everybody! Have a great day
 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Happy New Year to all :) more progress, clutch fully plumbed & bled along with brakes, awaiting new UJ's for the propshaft, I did but a pair in sept last year only to discover there for the drive shafts, DOH, hey ho, least I can use them as wont do any harm to change them out them, I see can a slight oil leak from the o/s inner drive shaft seal so will need to do that anyway, anyway some pics, cheers



 
Re: P6 V8 project: BW35 to SD1 LT77 5spd manual box swap

Propshaft now bolted on and modified the old auto exhaust bracket to fit to the manual box so the U-clamp fitted in the same position on the pipe. All looking good with 95% finished, need to make a bracket to re-fit the heat shield in-between the clutch master cylinder and the o/s exhaust manifold, need to re-bleed the brakes and fit new rear pads. I started it up last nite after nearly three months, few turns & fired into life :) . Will leave it on ramps/axel stands until I've done the brakes and rear pads, also want to wait until a dry day to test it out, hopefully this Sunday will be dry & sunny.

 
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