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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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41TRANSFER GEARBOX 10 REPAIR Refit 8.Clean oil seal recess. 9.Lubricate new input shaft oil seal with transfer gearbox oil. 10.Fit oil seal usingLRT-41-012. NOTE: Use end of tool marked ’FRONT’ to fit seal. 11.Position drive flange, fit new felt and steel washers. 12.PositionLRT-51-003fit new drive flange nut and tighten to148 Nm (109 lbf.ft). 13.Align marks and position front propeller shaft to output flange. Fit new nuts and tighten to48 Nm (35 lbf.ft). 14.Fit underbelly panel.See CHASSIS AND BODY, Repair. 15.Check/top-up transfer gearbox oil.SEAL - REAR OUTPUT SHAFT Service repair no - 41.20.54 Remove 1.Loosen brake shoe adjuster bolt. 2.Remove rear propeller shaft.See PROPELLER SHAFTS, Repair.
TRANSFER GEARBOX 11 REPAIR 3.Remove screw securing brake drum. 4.Remove brake drum. 5.Restrain transfer gearbox drive flange using LRT-51-003, remove and discard drive flange nut, remove and discard steel and felt washers. 6.UsingLRT-99-500if necessary, remove drive flange from transfer gearbox. 7.Remove and discard rear output shaft oil seal from transfer gearbox. Refit 8.Clean seal recess. 9.Lubricate new oil seal with transfer gearbox oil.
41TRANSFER GEARBOX 12 REPAIR 10.Fit new seal usingLRT-41-012. NOTE: Use end of tool marked’REAR’to fit seal. 11.Position drive flange, fit new felt and steel washers. 12.PositionLRT-51-003fit and tighten new drive flange nut to148 Nm (109 lbf.ft). 13.Position brake drum and tighten screw. 14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then back off 1 1/2 turns. 15.Check that brake drum is free to rotate. 16.Fit propeller shaft.See PROPELLER SHAFTS, Repair. 17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING Service repair no - 41.20.55 Remove 1.Drain transfer gearbox oil.See MAINTENANCE , 2.Remove rear output shaft seal.See this Section. 3.Mark output shaft housing to main casing for assembly purposes. 4.Note position of shoulder bolt, remove 6 bolts securing housing to main casing. Refit 5.Clean output shaft housing, mating face on main casing and sealant from bolt threads. 6.Apply Hylosil RTV 102 to mating flange on output shaft housing. 7.Fit output shaft housing to main casing ensuring that splines of output shaft are engaged in differential. 8.Apply Loctite 290 to bolt threads. 9.Fit bolts and tighten by diagonal selection to45 Nm (33 lbf.ft). 10.Fit rear output shaft seal.See this Section. 11.Fill transfer gearbox with oil.See MAINTENANCE ,
TRANSFER GEARBOX 13 REPAIR SWITCH - LOW DETECT Service repair no - 41.30.05 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 lever aside. 10.Remove 13 screws securing tunnel cover. 11.Release and remove tunnel cover.12.Release switch multiplug from bracket on transfer gearbox, disconnect from harness. 13.Remove switch. Refit 14.Clean switch and mating face on transfer gearbox. 15.Fit nut/spacer to switch with counterbore positioned towards switch head. 16.Apply Hylomar PL32 sealant to switch threads. 17.Fit switch and tighten to24 Nm (19 lbf.ft). 18.Connect multiplug to harness. 19.Fit and align tunnel cover, fit and tighten screws. 20.Position hand-brake lever and tighten bolts to25 Nm (18 lbf.ft). 21.Secure bulkhead carpet to LH side of tunnel. 22.Position relay/fuse panel, fit spacers and tighten screws. 23.Fit insulation pad around gear levers. 24.Fit gear lever (s) gaiter. 25.Fit gearbox tunnel carpet. 26.Fit gear lever knobs. 27.Reconnect battery negative lead. 28.Fit battery cover.
47 - PROPELLER SHAFTS CONTENTS Page REPAIR PROPELLER SHAFT - FRONT 1........................................................................... PROPELLER SHAFT - REAR 1.............................................................................. OVERHAUL PROPELLER SHAFT - FRONT 1........................................................................... PROPELLOR SHAFT - REAR 2.............................................................................
PROPELLER SHAFTS 1 REPAIR PROPELLER SHAFT - FRONT Service repair no - 47.15.02 Remove 1.Remove underbelly panel.See CHASSIS AND BODY, Repair. NOTE: To remove the underbelly panel, the propeller shaft has to be released from the front differential flange. 2.Mark propeller shaft to transfer gearbox. 3.Remove 4 nuts securing propeller shaft to transfer gearbox flange. 4.Remove propeller shaft. Refit 5.Clean propeller shaft flanges and mating faces. 6.Position propeller shaft to transfer gearbox flange and tighten nuts to48 Nm (35 lbf.ft). 7.Fit underbelly panel.See CHASSIS AND BODY, Repair.PROPELLER SHAFT - REAR Service repair no - 47.15.03 Remove 1.Raise rear of vehicle. WARNING: Support on safety stands. 2.Using a centre punch, mark relationship of propeller shaft flanges. 3.Remove 4 nuts securing propeller shaft to park brake flange. NOTE: Rotation of propeller shaft may be required during the above procedure. 4.Remove 4 nuts and bolts securing propeller shaft to rear axle flange. NOTE: Rotation of propeller shaft may be required during the above procedure. 5.Release propeller shaft from park brake. 6.Remove propeller shaft.
47PROPELLER SHAFTS 2 REPAIR Refit 7.Grease propeller shaft universal joints. 8.Grease propeller shaft spline. 9.Clean propeller shaft flange mating faces. 10.Fit propeller shaft to park brake flange bolts. NOTE: Ensure relationship marks align. 11.Position propeller shaft to rear axle flange and fit bolts. 12.Fit nuts and bolts securing propeller shaft to rear axle flange and tighten to48 Nm (35 lbf.ft). NOTE: Rotation of propeller shaft may be required during the above procedure. 13.Fit nuts securing propeller shaft to park brake and tighten to48 Nm (35 lbf.ft). NOTE: Rotation of propeller shaft may be required during the above procedure. 14.Remove stand(s) and lower vehicle.
PROPELLER SHAFTS 1 OVERHAUL PROPELLER SHAFT - FRONT Service repair no - 47.15.11 Remove 1.Remove front propeller shaft.See Repair. 2.Thoroughly examine universal joints for signs of damage or wear. 3.Clean universal joint bearing cups and circlips. CAUTION: To ensure correct assembly and reduce possibility of imbalance, before removing propeller shaft joint mark position of spider pin relative to journal yoke ears. 4.Remove circlips. 5.Note position and remove grease nipple. 6.Tap yokes to eject bearing cups. 7.Remove bearing cups. 8.Remove spider. 9.Clean yokes and bearing cup locations.Refit 10.Remove bearing cups from new spider. 11.Check all needle rollers are present and positioned in bearing cups. 12.Enter new spider with seals into yokes of propeller shaft flange. 13.Partially insert one bearing cup into flange yoke and enter spider trunnion into bearing cup. 14.Insert opposite bearing cup into flange yoke. 15.Press both cups into place. 16.Press each cup into its respective yoke up to lower land of circlip groove. Damage may be caused to cups and seals if cups pass this point. 17.Fit circlips and check no end float exists. 18.Fit grease nipple and lubricate 19.Repeat instructions for opposite end of propeller shaft as described in 1 to 9. 20.Fit front propeller shaft.See Repair.