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

41TRANSFER GEARBOX
2
ADJUSTMENT
12.Remove clevis pin clip and clevis pin securing
high-low selector linkage to lever.
13.Select neutral in transfer gearbox.
14.Move gear lever to neutral position.
15.Align linkage and check that clevis pin passes
through linkage without binding.
16.If binding occurs, adjust linkage until clevis pin
passes through without binding.
17.Fit clevis pin and clevis pin clip.
18.Tighten locknut.
19.Fit and align tunnel cover and secure with
screws.
20.Position hand-brake lever...

TRANSFER GEARBOX
1
REPAIR BOTTOM COVER - TRANSFER GEARBOX -
RESEAL
Service repair no - 41.20.06
1.Raise vehicle on ramp.
2.Remove 6 bolts securing rear underbelly panel
and remove panel.
3.Drain transfer gearbox oil.
4.Remove 10 bolts securing bottom cover to
transfer gearbox and remove cover.
Refit
5.Clean bottom cover and mating face on transfer
gearbox.
6.Clean bolt threads.
7.Apply Loctite 290 to bolt threads.
8.Apply Hylosil RTV sealant to bottom cover
sealing face.
9.Position bottom cover, fit...

41TRANSFER GEARBOX
2
REPAIR
13.Release handbrake outer cable from heelboard.
14.Remove breather pipe banjo bolt from transfer
gearbox high/low cross shaft housing and
discard sealing washers.
15.Remove retaining clip and disconnect high/low
operating rod from lever.
16.Remove cooling fan.See COOLING SYSTEM,
Repair.
17.Remove front exhaust pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
18.Drain transfer gearbox oil.
19.Remove 3 nuts securing intermediate silencer to
tail pipe.
20.Release intermediate...

TRANSFER GEARBOX
3
REPAIR
25.Remove retaining clip at lower end of pivot arm
and disconnect differential lock control operating
rod.
26.Remove 4 central bolts from transfer gearbox
bottom cover, position support plateLRT-99-010
to transfer gearbox and tighten bolts.
27.Position gearbox support jack and secure
support plate to jack using 4 bolts.
28.Support the weight of the transfer gearbox.
29.Remove 4 nuts securing LH and RH mountings
to chassis and transfer gearbox mounting
brackets.
30.Remove 8 bolts...

41TRANSFER GEARBOX
4
REPAIR
32.Remove retaining nut and release battery earth
lead from transfer gearbox.
33.Release body harness clips from bracket on top
of transfer gearbox.
34.Lower gearbox jack sufficiently to allow transfer
gearbox lever to clear tunnel.
35.Disconnect Lucars from differential lock warning
lamp switch and multiplug from low ratio detect
switch, and release multiplug from bracket.
36.Remove bolt and release earth leads from RH
side of transfer gearbox.
37.Move the high/low selector...

TRANSFER GEARBOX
5
REPAIR
43.If transfer gearbox is to be refitted, remove and
discard input shaft oil seal.
Refit
44.Clean mating faces of main gearbox extension
case and transfer gearbox.
45.Remove all traces of sealant from threads of
transfer gearbox securing bolts and studs.
46.Clean input shaft oil seal recess in transfer
gearbox.
47.Lubricate new input shaft oil seal with transfer
gearbox oil.
48.Using toolLRT-37-014, fit input shaft oil seal, lip
side facing inwards.49.Ensure guide...

41TRANSFER GEARBOX
6
REPAIR 71.Release propeller shaft, align flange markings
and connect to studs.
72.Fit nuts securing propeller shaft and tighten to48
Nm (33 lbf.ft).
73.Clean front propeller to transfer gearbox flange
mating faces.
74.Fit propeller shaft, align flange markings and
tighten nuts to48 Nm (33 lbf.ft).
75.Using new gasket, fit intermediate silencer and
tighten nuts to25 Nm (18 lbf.ft).
76.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
77.Refill transfer gearbox with...

TRANSFER GEARBOX
7
REPAIR SWITCH - DIFFERENTIAL LOCK WARNING LAMP
Service repair no - 41.20.34
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove gear lever knobs.
4.Remove gearbox tunnel carpet.
5.Remove gear lever (s) gaiter.
6.Release and remove insulation pad from around
gear levers.
7.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
8.Release bulkhead carpet from LH side of tunnel
and move aside.
9.Remove 2 bolts securing hand-brake lever to
body and move...

41TRANSFER GEARBOX
8
REPAIR 17.Apply Hylomar PL32 sealant to switch threads.
18.Position switch into gearbox housing until
locknut/spacer bottoms out on housing.
19. Switches fitted with spacer:Tighten spacer
securing differential lock switch to11 Nm (8
lbf.ft).
20.Connect Lucars to switch.
21. Switches fitted with locknut:Adjust switch.
See Adjustment.
22.Fit and align tunnel cover, fit and tighten screws.
23.Fit hand-brake lever and tighten bolts to25 Nm
(18 lbf.ft).
24.Secure bulkhead carpet to LH...

TRANSFER GEARBOX
9
REPAIR SEAL - FRONT OUTPUT SHAFT
Service repair no - 41.20.51
Remove
1.Position vehicle on 4 post ramp.
2.Remove underbelly panelSee CHASSIS AND
BODY, Repair.
3.Mark front propeller shaft to transfer gearbox
flanges for reassembly purposes.
4.Remove and discard 4 nuts securing front
propeller shaft to transfer gearbox drive flange,
and release propeller shaft from flange.
5.Restrain transfer gearbox drive flange using
LRT-51-003, remove and discard drive flange
nut, remove and discard...