Land Rover Defender V8i Workshop Supplement Rover Manual

							44AUTOMATIC GEARBOX
12
REPAIR 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
46 Nm (34 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.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 NEW 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
9Nm
(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. 
						

							AUTOMATIC GEARBOX
13
REPAIR 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 (34 lbf.ft).
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; Refit
166.Refill transfer gearbox oil.See MAINTENANCE
, under vehicle maintenance
167.Refill gearbox oil.See 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 70............................................................ 52
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
Drain plug - fluid pan 43........................................................ 22
Mounting screws for fluid pan 8.......................................... 6
Drive plate to converter 45*.................................................... 33*
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
Fluid screen bolts 8............................................................. 6
Pump housing to intermediate pipe 10.................................. 7
Propeller shaft nuts 47.......................................................... 35
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 
						

							51 - REAR AXLE AND FINAL DRIVE
CONTENTS
Page
REPAIR
DIFFERENTIAL PINION OIL SEAL 1..................................................................... 
						

							REAR AXLE AND FINAL DRIVE
1
REPAIR DIFFERENTIAL PINION OIL SEAL
Service repair no - 51.20.01
Remove
1.Raise rear of vehicle.
WARNING: Do not work under a vehicle
supported only by a jack. Always support
the vehicle on safety stands.
2.Reference mark the propeller shaft flanges for
reassembly.
3.Remove 4 nuts and bolts securing propeller
shaft to differential housing.
4.Release propeller shaft and tie aside.
5.UsingLRT-51-003to restrain the pinion flange,
remove bolt securing pinion flange.
6.Remove pinion flange.
7.Position container to catch oil spillage.
8.Using a suitable lever, remove and discard
pinion oil seal.
CAUTION: Take care to avoid damage to
oil seal recess. 
						

							51REAR AXLE AND FINAL DRIVE
2
REPAIR Refit
9.Clean pinion oil seal recess and pinion flange.
10.Lubricate NEW oil seal lip with clean oil.
11.UsingLRT-51-010fit pinion oil seal.
12.Fit pinion flange.
13.Restrain flange usingLRT-51-003and fit bolt.
Tighten bolt to
100 Nm (74 lbf.ft).
14.Position propeller shaft to differential housing
and align reference marks.
15.Fit flange bolts and tighten to
48 Nm (35 lbf.ft).
16.Remove stands and lower vehicle.
17.Top-up differential oil level. 
						

							54 - FRONT AXLE AND FINAL DRIVE
CONTENTS
Page
REPAIR
DIFFERENTIAL PINION OIL SEAL 1.....................................................................