Hi. My last post about a purchase desicion of a D1 200 TDI was left without answer, I guess this is moslty an American forum and y'all trucks are 4.0 automatics.... But still, now that I bought a '93 5-door turbodiesel with a 5-speed I have another question: what do I need to know to swap out the tranny? My truck came with a bad LT77 gearbox, the only gears that are working are Reverse, 1-st and barely 3-rd. That's it, it wasn't much fun driving this thing home. Yesterday a got a "new" LT77 box, supposedly in fully working condition. So, generally speaking, what do I need to have to even start contemplating the job? Some kind of gaskets where it connects to the engine and to the transfer case? Any special tools that I may not have? How complicated would this be aside from the box weighing over 100 lbs and all? I need to change the bell housings on it, are there any special gaskets for that? Any kind of silicone that needs or can be used to seal things up? I'm pretty much a dumbass at this, never done anything more complicated that a spark plug/ignition coil change, but I can have a few helpers and I have a garage with a 24" x 24" square hole in the floor and a crawl space beneath. Bought this truck and the box relatively cheap, and tryin' to invest as little money as possible at the beginning. Otherwise a nice truck, the former owner looked after it, but ended up bying a an LR3 TD5.
Thanks

 

The workshop manual pretty much covers it.
I'd consider changing the output shaft seal while you have the "new" LT77 on the bench.