Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual

37MANUAL GEARBOX
6
REPAIR MECHANISM AND HOUSING - GEAR SELECTOR -
RESEAL
Service repair no - 37.16.37.01
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever gaiter(s).
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Remove 4 bolts securing gear change...

MANUAL GEARBOX
7
REPAIR GEARBOX
Service repair no - 37.20.02.99
Remove
1.Disconnect battery negative lead.
2.Remove gear lever and transfer gearbox lever
knobs.
3.Remove gearbox tunnel carpet.
4.Remove gear lever cover.
5.Remove nut and washer securing gear lever to
lower splined lever.
6.Mark gear lever spline setting to lower lever and
remove lever.
7.Release and remove insulation pad from tunnel.
8.Remove trim stud and lift up handbrake gaiter for
access to clevis pin.
9.Remove split pin, clevis pin,...

37MANUAL GEARBOX
8
REPAIR
12.Remove 13 screws securing tunnel cover.
13.Release and remove tunnel cover.
14.Remove cooling fan.See COOLING SYSTEM,
Repair.
15.Remove air filter.See FUEL SYSTEM, Repair.
16.Remove 2 upper bolts securing clutch housing to
engine.
17.Remove bolt securing shim to clutch housing.
18.Release gearbox breather pipes from clips on
heater hose.
19.Remove starter motor.See ELECTRICAL,
Repair.
20.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
21.Drain gearbox...

MANUAL GEARBOX
9
REPAIR
26.Remove 4 nuts securing front propeller shaft to
transfer gearbox, release propeller shaft from
output drive flange.
27.Remove 4 nuts, release rear propeller shaft from
brake drum.
28.Remove 2 bolts securing clutch slave cylinder,
release slave cylinder and position aside.
29.Fit support plateLRT-99-007to gearbox jack.
30.Position gearbox jack and support plate to
gearbox and secure with 3 bolts.
31.Support the weight of gearbox.
32.Remove 4 nuts securing LH and RH mountings
to...

37MANUAL GEARBOX
10
REPAIR
34.Pull handbrake cable through heel board.
35.Disconnect multiplug from speed sensor and
release harness from clip on transfer gearbox.
36.Remove retaining nut and release battery earth
lead from transfer gearbox.
37.Release body harness clips from bracket on top
of transfer gearbox.
38.Lower gearbox jack sufficiently to allow transfer
gearbox lever to clear tunnel.
39.Disconnect 2 Lucars from differential lock switch,
multiplug from reverse light switch and multiplug
from low...

MANUAL GEARBOX
11
REPAIR Refit
44.Clean gearbox to engine mating faces, dowels
and dowel holes.
45.With assistance raise gearbox on jack and align
to clutch and engine.
46.Fit lower bolts securing clutch housing to engine
and tighten to50 Nm (37 lbf.ft).
NOTE: Do not fit upper bolts at this stage.
47.Fit earth leads and secure with bolt.
48.Connect Lucars to differential lock switch,
multiplug to reverse light switch, position
multiplug to bracket and connect low ratio detect
multiplug - if fitted....

37MANUAL GEARBOX
12
REPAIR SWITCH - REVERSE LIGHT
Service repair no - 37.27.01
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever (s) gaiter.
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Disconnect reverse light switch multiplug.
10.Remove switch...

41 - TRANSFER GEARBOX
CONTENTS
Page
ADJUSTMENT
DIFFERENTIAL LOCK WARNING LAMP SWITCH 1.............................................
HIGH/LOW SELECTOR LINKAGE 1......................................................................
REPAIR
BOTTOM COVER - TRANSFER GEARBOX - RESEAL 1......................................
TRANSFER GEARBOX 1.......................................................................................
GASKET - REAR COVER PLATE...

TRANSFER GEARBOX
1
ADJUSTMENT DIFFERENTIAL LOCK WARNING LAMP SWITCH
Service repair no - 41.20.36
Adjust
NOTE: This procedure is only necessary
for switches fitted with a locknut in place
of the threaded spacer.
1.Move differential lock selector fork to differential
locked position.
2.Connect a 12V test lamp and battery to
differential lock warning lamp switch.
3.Screw switch in until test lamp is illuminated then
screw switch in a further 1/2 turn; tighten locknut.
4.Disengage differential lock, check...