Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							44AUTOMATIC GEARBOX
8
REPAIR
33.Using a centre punch, mark relationship between
front propeller shaft to transfer box flanges.
34.Using a centre punch, mark relationship between
rear propeller shaft to brake drum flanges.
35.Remove 4 nuts securing front propeller shaft to
transfer box flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
36.Release propeller shaft from transfer box flange
bolts and tie aside.
37.Remove 4 nuts securing rear propeller shaft to
brake drum flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
38.Release propeller shaft from brake drum bolts
and tie aside.
39.Remove 7 bolts securing bell housing closing
plate and remove plate.
40.Remove 3 bolts securing bell housing access
plate and remove plate.
41.Mark relationship between converter and drive
plate.
42.Rotate crankshaft to access drive plate to
converter fixing.
43.Remove 4 bolts securing drive plate to
converter.
44.Fit suitable piece of wood through bell housing
access hole to retain converter. 
						

							AUTOMATIC GEARBOX
9
REPAIR
45.Remove clamp bolt securing gearbox cooler
pipes to engine sump bracket.
46.Loosen gearbox cooler pipe unions and
disconnect from gearbox.
47.Remove and discard O rings from pipes.
CAUTION: Plug the connections.
48.Tie cooler pipes aside.
49.Loosen gearbox filler tube union and remove
from fluid pan.
50.Remove and discard O ring from union.
CAUTION: Plug the connections.
51.Remove split pin from selector cable yoke and
collect washer.
52.Release yoke from lever.
53.Remove bolt securing selector outer cable clamp
to transfer box LH mounting.
54.Remove nut securing oxygen sensor multiplug
bracket from transfer box earth bolt and collect
bracket.
55.Remove nut securing earth strap to transfer box
and release strap. 
						

							44AUTOMATIC GEARBOX
10
REPAIR
56.Release hand brake outer cable from body.
57.Remove bolt securing earth lead to RH side of
transfer box.
58.Fit transmission cradleLRT-99-008Ato
transmission jack.
59.Fit and tighten bolts securing cradle to jack.
60.Remove 2 lower bolts securing transfer box rear
cover.
61.Collect hand brake cable heat shield.
62.Raise jack and align cradle to transmission.
63.Refit previously removed transfer box rear cover
bolts to secure cradle.
64.Remove 2 nuts and bolts securing heat shield to
transfer box LH mounting bracket.
65.Remove heat shield.
66.Remove 3 nuts and bolts securing transfer box
LH mounting bracket to chassis.
67.Release earth lead from fixing.
68.Remove nut securing transfer box RH mounting.
69.Remove 3 nuts and bolts securing transfer box
RH mounting bracket to chassis.
70.Remove transfer box RH mounting bracket and
collect flexible mount heat shield.
71.Lower transmission on jack to access harness
connectors. 
						

							AUTOMATIC GEARBOX
11
REPAIR 72.Disconnect the following multiplugs/connectors
from transfer box:
Speed transducer
Parking solenoid
Neutral detection switch
Differential lock
Temperature sensor switch
73.Remove 2 cable ties securing harness to
transfer box.
74.Position jack to support engine sump.
CAUTION: Use a block of wood or hard
rubber pad to protect sump.
75.Remove 2 remaining bell housing to engine
bolts.
76.With assistance, lower transmission and engine
jacks until hi-low selector lever is clear of
transmission tunnel aperture.
77.Separate transmission from engine and lower on
jack.
78.Remove transmission assembly from beneath
ramp.
79.Position lifting eyes to transmission and secure
with bolts.
80.Fit lifting chains to eyes and connect.
81.Position lifting hoist and connect lifting chains.
82.Raise hoist until chains are taught.
83.Remove bolts securing cradle to transfer box.
84.Raise transmission from cradle.
85.Refit transfer box rear cover plate bolts.
86.Lower transmission assembly onto work bench.
87.Disconnect lifting chains from eyes.
88.Remove bolts securing eyes to transmission and
remove eyes.
Refit
89.Position lifting eyes to transmission and secure
with bolts.
90.Connect lifting chains to eyes.
91.Raise transmission assembly from bench and
position above transmission cradle.
92.Remove 2 transfer box rear cover plate bolts.
93.Lower transmission onto cradle, align to transfer
box rear cover plate and secure with previously
removed bolts.
94.Lower hoist and disconnect lifting chains from
eyes.
95.Remove chains from hoist.
96.Remove bolts securing lifting eyes to
transmission and remove eyes.97.Position transmission assembly beneath vehicle.
98.Clean engine to gearbox mating faces.
99.Clean engine to gearbox dowels and dowel
holes.
100.With assistance, raise transmission on jack and
position to engine dowels.
101.Fit 2 lower bell housing to engine bolts and
tighten to
45 Nm, 33 lbf ft.
102.With assistance, raise engine and transmission
jacks to position transmission assembly.
NOTE: Do not fully raise transmission at
this stage as access is required for
connection of connectors to transfer box.
103.Remove engine jack from beneath vehicle.
104.Secure harness to transfer box with cable ties.
105.Connect multiplugs/connectors to transfer box.
106.Raise transmission and align to mounting
locations.
107.Fit transfer box RH flexible mounting heat shield
and mounting bracket.
108.Align RH mounting to chassis and secure with
nuts and bolts.
109.Fit and tighten nut securing RH mounting.
110.Align LH mounting to chassis and secure with
nuts and bolts.
NOTE: Position earth lead to mounting
fixing.
111.Position heat shield to LH mounting bracket and
secure with fixings.
112.Remove bolts securing transmission cradle to
transfer box.
113.Lower transmission jack and remove from
beneath ramp.
114.Fit and tighten transfer box rear cover bolts.
NOTE: Position heat shield to cover plate
fixing.
115.Position earth lead to RH side of transfer box
and secure with bolt.
116.Feed hand brake outer cable through body.
NOTE: Apply a soap solution to aid fitment
of cable to body.
117.Position earth strap to transfer box stud and
secure with nut.
118.Fit oxygen sensor multiplug bracket to transfer
box earth bolt and secure with nut. 
						

							44AUTOMATIC GEARBOX
12
REPAIR 119.Position selector outer cable clamp to transfer
box LH mounting and secure with bolt.
120.Position selector cable yoke to lever, fit washer
and secure with split pin.
121.Remove plug from transmission filler tube union.
122.Lubricate new O ring with gearbox oil and fit to
filler tube.
123.Fit filler tube to gearbox and tighten union.
124.Release cooler pipes and remove plugs from
connections.
125.Lubricate new O rings with gearbox oil and fit to
pipes.
126.Position cooler pipes to gearbox and tighten
unions.
127.Position cooler pipes to engine sump bracket, fit
clamp and secure with bolt.
128.Remove piece of wood from bell housing access
hole.
129.Align converter to drive plate.
130.Fit bolts securing converter to drive plate and
tighten to
45 Nm, 33 lbf ft.
NOTE: Rotate crankshaft during the above
procedure.
131.Fit bell housing access plate and secure with
bolts tightened to
9 Nm, 7 lbf ft..
132.Clean bell housing cover plate and mating face.
133.Fit plate and secure with bolts tightened to
9
Nm, 7 lbf ft.
134.Clean rear propeller shaft to brake drum mating
faces.
135.Release rear propeller shaft, align flange
markings and connect to studs.
136.Fit nuts securing rear propeller shaft to brake
drum and tighten to
47 Nm, 35 lbf ft.
NOTE: Rotate propeller shaft to gain
access to all fixings.
137.Clean front propeller shaft to transfer box mating
faces.
138.Release front propeller shaft, align flange
markings and connect to studs.
139.Fit nuts securing front propeller shaft to transfer
box and tighten to
47 Nm, 35 lbf ft.
NOTE: Rotate propeller shaft to gain
access to all fixings.
140.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.141.Fit crossmember and align fixings.
142.Remove body jack.
143.Fit nuts and bolts securing chassis
crossmember, but do not tighten.
144.Fit LH and RH catalyst heat shields to chassis, fit
bolts but do not tighten.
145.Align LH and RH catalyst heat shields to chassis
crossmember fixings and tighten all fixings.
146.Clean intermediate to tail pipe flange.
147.Fit intermediate pipe to mounting rubber,
connect to tail pipe and secure with nuts.
148.Fit exhaust front pipe.
See EMISSION
CONTROL, Repair, front pipe/catalytic
converter; Refit
149.Lower vehicle.
150.Fit bolts securing bell housing to engine and
tighten to
46 Nm.
NOTE: Align harness brackets to 2
uppermost bell housing retaining bolts.
151.Align breather pipe P clips to rear of RH
cylinder head and secure with bolt.
152.Secure kick-down outer cable to clip on rear of
LH cylinder head.
153.Secure kick-down outer cable to abutment
bracket.
154.Secure kick-down outer cable lock nut.
155.Align kick-down cable to linkage and secure
clevis pin.
156.Adjust kick-down cable.
See Adjustment,
kickdown cable adjustment
157.Fit upper fan cowl and secure with clips.
158.Align fan cowl to upper retaining brackets and
secure with screws.
159.Align hand brake cable to lever, fit clevis pin and
secure with split pin.
160.Position hand brake gaiter and secure with trim
studs.
161.Secure gearbox and transfer box breather pipes
to harness with cable ties.
162.Connect inhibitor/reverse light switch multiplug.
163.Fit hi-low selector housing cover to tunnel.
164.Fit carpet to transmission tunnel.
165.Fit centre console.
See CHASSIS AND BODY,
Repair, centre console
166.Refill transfer gearbox oil.See SECTION 10,
Maintenance, under vehicle maintenance
167.Refill gearbox oil.See SECTION 10,
Maintenance, under vehicle maintenance
168.Reconnect battery negative lead.
169.Select Hi range gear and park.
170.Remove vehicle from ramp. 
						

							AUTOMATIC GEARBOX
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Nm lbf ft
Coupling shaft to mainshaft 42*.............................................. 30*
Filler tube to sump 68............................................................ 50
Gear change lever to gearbox 25.......................................... 18
Cooler pipe adaptor to gearbox 42........................................ 30
Securing screws - clutch F 10............................................... 7
Securing screw - parking pawl 10......................................... 7
Securing screws - pump 10................................................... 7
Intermediate plate plugs (M20) 50........................................ 35
Intermediate plate plugs (M14) 40........................................ 30
Bell housing mounting bolts 46............................................. 34
Governor mounting screws 10.............................................. 7
Extension housing bolts 23................................................... 17
Control unit mounting bolts 8.............................................. 6
Draib plug - fluid pan 10........................................................ 7
Mounting screws for sump 8............................................... 6
Drive plate to converter 39*.................................................... 29*
Gearbox to engine 42............................................................ 31
Strut (threaded end) 42......................................................... 31
Bottom cover to converter housing 9.................................. 7
Cover - converter housing 9................................................ 7
Drive plates to crankshaft adaptor 40*................................... 30*
Adaptor to crankshaft 84....................................................... 62
NOTE: * These bolts MUST have threads coated with Loctite 270 prior to assembly.
Torque values below are for all screws and bolts used except for those that are specified otherwise.
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 Nm lbf ft
1/4 9........................................................................... 7
5/16 24......................................................................... 18
3/8 39........................................................................... 28
7/16 78......................................................................... 58
1/2 90........................................................................... 65
5/8 136........................................................................... 100 
						

							44AUTOMATIC GEARBOX
2
SPECIFICATIONS, TORQUE ZF GEARBOX DATA
Axial end float 0.2 - 0.4 mm.................................................................... 0.008 - 0.016 in
From torque converter boss to torque converter
housing face 50 mm..................................................................... 1.968 in
Freewheel cage assembly to ring gear;
minimum clearance 0.1 mm.......................................................... 0.004 in
Output shaft dimension above cylinder F assembly 10.00 mm......... 0.394 in
A cylinder maximum protrusion above gearbox front
face 8.5 mm.................................................................................. 0.335 in 
						

							PROPELLER SHAFTS
1
DESCRIPTION AND OPERATION PROPELLER SHAFT ALIGNMENT
Description
The front and rear propeller shafts have non-constant
velocity Hooks type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and sealed.
The front shaft is a solid bar, which is shorter than the
rear, with the joints Phased at each end, A and B
mis-aligned. The phasing is necessary on the front
shaft only to allow for greater variation in angular
changes.
The rear shaft is a tube fitted with a conventional joint
at gearbox end and the sliding joint sealed with a
rubber gaiter.
Propeller shaft
1.Flanged yoke
2.Grease nipple
3.Journal spider
4.Needle roller bearing
5.Circlip
6.Splined shaft
7.Rubber gaiter (dust cap)
8.Splined shaft 
						

							PROPELLER SHAFTS
1
FAULT DIAGNOSIS VIBRATION HARSHNESS
1.Check that the propeller shaft universal joints
and sliding splines are not siezed or worn and
that the shafts are correctly aligned.
NOTE: In the event that both shafts are
satisfactory, but the vibration/harshness is
still present, the transfer box operation
and balance of the road wheels should be
checked.
For transfer gearbox operation.
See TRANSFER
GEARBOX, Description and operation, LT230Q
Transfer Gearbox
For balance of road wheels.See WHEELS AND
TYRES, Repair, Wheel Balancing 
						

							PROPELLER SHAFTS
1
REPAIR PROPELLER SHAFTS
Service repair no - 47.15.02 - Front
Service repair no - 47.15.03 - Rear
Remove
1.Place vehicle over pit or on a ramp [hoist].
2.Remove nuts from each end of propeller shaft.
Remove shaft.
3.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
Overhaul
Service repair no - 47.15.11 - Front
Service repair no - 47.15.12 - Rear
4.Thoroughly examine universal joint for signs of
damage or wear. Replace if necessary.
5.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 lubricator relative to journal
yoke ears.
6.Remove circlips, and grease nipple.
7.Tap yokes to eject bearing cups.
8.Remove bearing cups and spider.
9.Repeat instructions 4 to 7 for opposite end of
propeller shaft if necessary.
10.Clean yokes and bearing cup locations.
Assemble
11.Remove bearing cups from new spider.
12.Check all needle rollers are present and
positioned in bearing cups.
13.Ensure bearing cups are one-third full of
lubricant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
14.Enter new spider with seals into yokes of sliding
member flange.
15.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
16.Insert opposite bearing cup into flange yoke.
17.Press both cups into place.