Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							TRANSFER GEARBOX
3
REPAIR
22.Using a centre punch, mark relationship between
front propeller shaft and transfer box drive
flanges and rear propeller shaft and brake drum
drive flanges.
23.Remove 4 nuts securing front propeller shaft to
transfer box flange. Release propeller shaft from
flange and tie aside.
24.Remove 4 nuts securing rear propeller shaft to
brake drum flange. Release propeller shaft from
flange and tie aside.
25.Remove nut securing tie bar to gear box and 2
bolts securing tie bar to transfer box.
26.Remove tie bar.
27.Remove bolt securing selector outer cable clamp
to transfer gearbox LH mounting.
28.Remove nut securing oxygen sensor multiplug
bracket to transfer gearbox earth bolt and collect
bracket.
29.Remove nut securing earth strap to transfer
gearbox and release strap. 
						

							41TRANSFER GEARBOX
4
REPAIR
30.Release handbrake outer cable from body.
31.Remove bolt securing ground lead to RH side of
transfer gearbox.
32.Remove bolt securing handbrake cable heat
shield. Remove heat shield.
33.Position adaptor plate,LRT-99-010, and secure
to transmission hoist with 4 bolts.
34.Remove 4 central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer box.
35.Adjust hoist to take weight of transfer gearbox.
36.Remove 2 nuts and bolts securing heat shield to
transfer gearbox LH mounting bracket. Remove
heat shield.
37.Remove 3 nuts and bolts securing LH gearbox
mounting bracket to chassis. 
						

							TRANSFER GEARBOX
5
REPAIR
38.Remove nut securing transfer gearbox RH
mounting to mounting rubber.
39.Remove 3 nuts and bolts securing transfer
gearbox mounting bracket to chassis. Remove
transfer box RH mounting bracket and collect
rubber mounting heat shield.
40.Lower transmission sufficiently to gain access to
harness connectors and transfer box breather
pipe connection.
41.Remove banjo bolt from transfer box breather
pipe and collect 2 sealing washers. Discard
sealing washers.
42.Remove retaining clip and disconnect high/low
lever from operating rod.
43.Remove 2 clips at lower end of pivot arm and
disconnect differential lock lever link.
44.Disconnect the following multiplugs/connectors
from transfer box:
Speed transducer
Parking solenoid
Neutral detection switch
Differential lock
Temperature sensor switch45.Remove 2 clips securing harness to transfer box.
46.Position a jack to support main gearbox.
CAUTION: Use a block of wood or hard
rubber pad to protect gearbox.
47.Remove nut and 4 bolts securing transfer box to
main gearbox extension case.
48.Fit 3 guide studs, LRT-41-009, through transfer
box bolt holes to support it during removal.
49.Lower hoist and withdraw transfer box from main
gearbox.
50.Remove transfer box.
Refit
51.Ensure joint faces of transfer box and main
gearbox are clean and guide studs, LRT-41-009,
are fitted to extension case.
52.Lubricate oil seal in joint face of transfer box.
53.Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
54.Remove guide studs, and secure transfer box to
main gearbox extension case. Tighten fixings to
45 Nm, 33 lbf/ft.
55.Connect muliplugs/connectors to transfer box.
56.Position breather pipe to transfer box, fit new
sealing washers and tighten banjo bolt to
15 Nm,
11 lbf ft.
57.Fit link to differential lock lever and pivot arm and
secure with retaining clips.
58.Connect high/low lever to operating rod and
secure with retaining clip.
59.Raise hoist and remove jack supporting main
gearbox.
60.Position RH mounting rubber heat shield and
mounting bracket and secure loosely with
retaining nut.
61.Align RH mounting bracket to chassis and
secure with nuts and bolts.
62.Tighten nut securing RH mounting.
63.Align LH mounting bracket to chassis and
secure with nuts and bolts.
NOTE: Position ground lead to mounting
bolt. 
						

							41TRANSFER GEARBOX
6
REPAIR 64.Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
65.Lower hoist and move aside.
66.Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to
25 Nm, 18 lbf/ft.
67.Position handbrake cable heat shield and tighten
bolt.
68.Position ground lead to RH side of transfer box
and tighten bolt.
69.Feed handbrake cable through body.
NOTE: Apply a soap solution to aid fitment
of cable.
70.Position ground strap to transfer box stud and
tighten nut.
71.Fit heated oxygen sensor multiplug bracket to
stud and tighten nut.
72.Position selector outer cable clamp to transfer
box LH mounting and tighten bolt.
73.Fit tie bar and tighten bolts and nut.
74.Clean rear propeller shaft and brake drum flange
mating faces.
75.Release propeller shaft, align flange markings
and connect to studs.
76.Fit nuts securing propeller shaft and tighten to
47
Nm, 33 lbf ft.
77.Clean front propeller shaft and transfer box
flange mating faces.
78.Release propeller shaft, align flange markings
and connect to studs.
79.Fit nuts securing propeller shaft and tighten to
47
Nm, 33 lbf ft.
80.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
81.Fit crossmember and tighten bolts.
82.Clean intermediate and tail pipe flanges.
83.Fit intermediate pipe to mounting rubber,
connect to tail pipe and tighten nuts.
84.Fit exhaust front pipe.
See EMISSION
CONTROL, Repair, front pipe/catalytic
converter
85.Refill transfer box with recommended oil.See
SECTION 10, Maintenance, under vehicle
maintenance
.
86.Lower vehicle ramp.
87.Fit upper fan cowl and secure clips.
88.Align fan cowl to upper retaining brackets and
tighten screws.
89.Align handbrake cable to lever, fit clevis pin and
secure with new split [cotter] pin.90.Position handbrake lever cover and secure with
trim studs.
91.Fit high-low selector housing cover to
transmission tunnel.
92.Fit carpet to transmission tunnel.
93.Fit centre console.
See CHASSIS AND BODY,
Repair, centre console
94.Reconnect battery negative lead.
95.Check park brake operation and adjust if
necessary.
See SECTION 10, Maintenance,
vehicle interior 
						

							TRANSFER GEARBOX
7
REPAIR SHIFTLOCK SOLENOID
Service repair no - 41.20.63
Remove
1.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre console
2.Remove carpet from transmission tunnel.
3.Remove 2 screws securing relay panel.
4.Retain 2 centre console screw brackets and
spacers.
5.Release connector J1962 from bracket on tunnel
cover and move relay panel aside to gain access
to tunnel cover top fixings.
6.Remove 15 screws securing tunnel cover.
7.Release and remove tunnel cover.
8.Disconnect shiftlock solenoid multiplug.
9.Remove 4 bolts and release solenoid cover from
transfer box.
10.Remove solenoid and washer.
11.Clean joint sealant from mating faces.
Refit
12.Apply Hylosil or equivalent sealant to mating
faces.
13.Fit solenoid. Ensure solenoid multiplug lead is
located in cover recess.
14.Secure solenoid cover to transfer box. Tighten
bolts to
9 Nm (7 lbf/ft).
15.Connect solenoid multiplug.
16.Fit tunnel cover.
17.Secure connector J1962 to bracket on tunnel
cover.
18.Position centre console screw bracket and
spacers and fit relay panel.
19.Fit tunnel carpet.
20.Fit centre console.
See CHASSIS AND BODY,
Repair, Centre console 
						

							41TRANSFER GEARBOX
8
REPAIR NEUTRAL SWITCH
Service repair no - 41.20.64
Remove
1.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre console
2.Remove carpet from transmission tunnel.
3.Remove 2 screws securing relay panel.
4.Retain 2 centre console screw brackets and
spacers.
5.Release connector (J1962) from bracket on
tunnel cover and move relay panel aside to gain
access to tunnel cover top fixings.
6.Remove 15 screws securing tunnel cover.
7.Release and remove tunnel cover.
8.Disconnect neutral switch multiplug.
9.Remove neutral switch from transfer box.
10.Clean sealant from switch.
Refit
11.Apply Hylomar PL32/L20 or equivalent sealant to
neutral switch.
12.Fit switch to transfer box and tighten to
25 Nm
(18 lbf/ft).
13.Connect switch multiplug.
14.Fit tunnel cover.
15.Secure connector (J1962) to bracket on tunnel
cover.
16.Position centre console screw bracket and
spacers and fit relay panel.
17.Fit tunnel carpet.
18.Fit centre console.
See CHASSIS AND BODY,
Repair, Centre console 
						

							TRANSFER GEARBOX
1
SPECIFICATIONS, TORQUE TORQUE VALUES
LT230Q Transfer gearbox
Nm lbf ft
Bottom cover to transfer case 25.......................................... 18
Transfer breather 15............................................................. 11
Transfer box front drive flange to drive shaft 45.................... 33
Transfer box rear drive flange to drive shaft 45..................... 33
Transfer box to gearbox extension case 45.......................... 33
NOTE: The following torque values are for screws and bolts not specified in the previous table.
METRIC Nm lbf ft
M5 6........................................................................... 5
M6 9........................................................................... 7
M8 25........................................................................... 18
M10 45......................................................................... 33
M12 90......................................................................... 65
M14 105......................................................................... 75
M16 180......................................................................... 130
UNC / UNF
1/4 9........................................................................... 7
5/16 25......................................................................... 18
3/8 40........................................................................... 30
7/16 80......................................................................... 60
1/2 90........................................................................... 65
5/8 135........................................................................... 100 
						

							AUTOMATIC GEARBOX
1
DESCRIPTION AND OPERATION DESCRIPTION
The automatic transmission is specially tailored version of the ZF 4HP22, used by many manufacturers of high
performance vehicles.
A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third
gears are reduction ratios but fourth is an overdrive gear for high speed cruising. A direct drive clutch, integral with
the torque converter operates to engage fourth gear.
The gear selector has seven positions as follows:
P = Park provides a mechanical lock on the output shaft.
R = Reverse gear.
N = Neutral.
D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1.
3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1.
2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1.
1 = Provides a 1st gear start with no up shifts, or 3-2-1.
All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output
shaft. 
						

							44AUTOMATIC GEARBOX
2
DESCRIPTION AND OPERATION Power flow
1st gear D selected
With D selected 1st gear engaged, clutches 4 and 11 are operative. The front planet gear carrier of gear set 9 is
locked against the housing through freewheel 15 when the engine is pulling but freewheels when the vehicle is
coasting. Epicyclic gear set 10 rotates as a solid unit with the front planet gear carrier. In selector position 1 with
1st gear engaged, clutch 8 operates to prevent the loss of drive on the overrun through freewheel 15, to provide
engine braking.
2nd gear D selected
Clutches 4, 6, 7 and 11 are engaged. Freewheel 15 overruns, the hollow shaft with the sun wheel of epicyclic gear
set 9 is locked. Epicyclic gear set 10 also rotates as a solid unit. 
						

							AUTOMATIC GEARBOX
3
DESCRIPTION AND OPERATION 3rd gear D selected
Clutches 4, 5, 7 and 11 are engaged. Freewheel 15 and 16 are overrun. Epicyclic gear set 9 and 10 rotate as a
solid unit at a ratio of 1:1.
4th gear D selected
Clutches 4, 5, 7 and 12 are engaged. Freewheel 14, 15 and 16 are overrun. Epicyclic gear set 9 rotates as a solid
unit. The hollow shaft with the sun wheel of epicyclic gear set 10 is locked.
Above a predetermined road speed, clutch 2 locks the gearbox power input direct to the engine, by-passing the
torque converter.