Land Rover Defender Workshop 1993 Rover Manual

							3. Clean all intermediate  gear components  and Intermediate  gear reassembly 
7. Check  for damage  to the  intermediate  shaft 
4. Fit new  circlips  into the intermediate  gear  thread and if necessary  clean up with  a fine 
5. Using  tools LST550 - 4 and  MS550  fit bearing 8. Lubricate  the taper  roller bearing  and 
intermediate  gear shaft. 
9. Insert  new bearing  spacer to gear  assembly, 
followed  by the  taper  roller bearings. 
lock plate.  Check  for damage  or wear  and 
replace  as necessary. 
cluster,  file or stone. 
tracks  into the intermediate  gear cluster. 
10. Fit dummy  shaft LST104 into the intermediate 
gear  cluster. 
11. Locate  the gear  assembly  into the transfer  box 
casing  from the 
bottom cover  aperture. 
12. Insert  intermediate  shaft from the front  of the 
transfer 
box casing,  pushing  the dummy  shaft 
right  through  as shown  and remove.  (Making 
sure  that the intermediate  gear cluster  meshes 
with  the input  gear and high  range  and low 
range  gears.) 
6. Fit the ‘O’ rings to the  intermediate  shaft and 
into  the intermediate  shaft bore at 
the front of 
the  transfer 
box casing.  
						

							LT230T TRANSFER GEARBOX 
13. Turn  the intermediate  shaft to allow  fitting of 20. Peen  the stake  nut by carefully  forming the 
retaining  plate.  collar of the  nut into  the intermediate  shaft 
14.  Fit 
retaining  plate and secure  with retaining  recess, as illustrated. 
bolt  and  washer. 
15. Fit the  intermediate  gear shaft  retaining  stake CAUTION:  A round  nose tool must  be used 
nut. for  this  operation  to avoid  splitting  the 
collar  of the  nut. 
Power  take - 
off cover  - reassemble 
21.  Clean  power  take - off cover and gasket  face. 
22.  Fit the  two  countersunk  screws and tighten. 
23.  Remove  the six bolts  from the bearing  support 
plate. 
24.  Apply  sealant  to the  cover  plate gasket  and fit 
it to the  bearing  support  plate. 
25.  Apply  Loctite 
290 to bolt  threads  and secure 
the  power  take 
- off cover with the six bolts 
and  washers. 
Bottom  cover - reassemble 
Adjusting  intermediate  gear torque  - 
to - turn 26. Clean  bottom  cover and gasket  face. 
27.  Apply  sealant  to cover  gasket  and 
fit to 
16.  Select  neutral.  transfer 
box casing. 
17.  Fit service 
tool LST105  to input  gear and  28. Apply  Loctite 290 to bolt  threads  and secure 
engage  spline. 
18.  Tie 
a length of string  to a split pin and  fit to 
the  service  tool as shown.  Attach the spring 
balance 
to the  string. 
19. To obtain  the correct  figures and to collapse 
the  spacer  within the intermediate  gear 
cluster,  tighten the intermediate  shaft nut until 
the  load 
- to - turn  has increased  by 3,7 kg (7 
Ib)  ± 1,63  kg (± 3 Ib)  on that  noted  when 
checking  input shaft  load 
- to - turn.  the 
bottom cover 
with SIX bolts and washers.  
						

							LT230T TRANSFER GEARBOX 
Differential lock switch  adjustment  Transmission 
brake drum - re-assemble. 
1. Select  differential  locked position  by moving 1. Clean  brake backplate  and oil catcher  and 
the  lock  taper  towards  the right  side 
of the  apply sealant to the catcher  joint face. 
transfer  box casing. 
2. Locate  brake backplate  on the  rear  output 
2. Apply  sealant to the differential lock warning  housing with the brake  operating  lever on the 
light  switch  and fit 
to the top  of the  front  right side of the transfer  box casing. 
output  housing. 
3. Secure  the backplate  (including the oil 
3. Connect  a test  lamp  circuit to the differential  catcher) with the four  special  bolts and tighten 
lock switch.  using a hexagonal  socket to the  specified 
4. Screw  in the  lock  switch  until the bulb  is  torque. 
illuminated. 
4. Clean  and fit brake  drum and secure  with two 
5. Turn in the switch  another  half a turn  and 
tighten  with the locknut  against the housing. 
6. Disconnect  the battery  and move the 
differential lock lever to the  left to disengage 
differential  lock. 
7. Clean the front  output  housing  side cover. 
8. Grease  and fit side  cover  gasket. 
9. Apply Loctite 290 to bolt  threads, fit side  cover 
and  secure  with seven  bolts and washers. 
countersunk screws.  
						

							LT230T TRANSFER GEARBOX 
13. Turn the intermediate  shaft to allow fitting of 20. Peen  the  stake nut  by  carefully  forming the 
retaining  plate.  collar 
of the 
nut into  the intermediate  shaft 
14. Fit retaining  plate and secure  with  retaining  recess,  as illustrated. 
bolt  and  washer. 
15. Fit the intermediate  gear  shaft retaining stake CAUTION:  A round nose tool must be used 
nut. for  this  operation to avoid  splitting  the 
collar 
of the  nut. 
Power  take 
- off cover - reassemble 
21. Clean  power take - off cover  and gasket face. 
22.  Fit the  two  countersunk  screws  and tighten. 
23.  Remove  the six bolts from  the bearing  support 
plate. 
24.  Apply  sealant  to  the cover plate gasket  and fit 
it  to  the  bearing  support  plate. 
25.  Apply  Loctite  290 to bolt  threads  and secure 
the  power  take 
- off cover  with  the  six bolts 
and  washers. 
Bottom cover - reassemble 
Adjusting  intermediate  gear torque 
- to - turn 26. Clean bottom  cover and gasket  face. 
27.  Apply  sealant 
to cover gasket  and fit to 
16. Select  neutral.  transfer  box casing. 
17.  Fit service  tool LST105  to input  gear  and  28. Apply  Loctite  290 to bolt  threads  and secure 
engage  spline. 
18.  Tie a length  of string  to a split  pin and  fit to 
the  service  tool as shown.  Attach  the  spring 
balance  to the string. 
19.  To obtain  the correct  figures and to  collapse 
the  spacer  within the intermediate  gear 
cluster,  tighten  the  intermediate  shaft nut until 
the  load 
- to - turn  has  increased  by 3,7  kg (7 
lb)  ±  1,63 kg (± 3 
lb) on  that  noted  when 
checking  input  shaft  load 
- to - turn.  the  bottom cover  with 
six bolts  and washers.  
						

							LT230T TRANSFER GEARBOX 
Differential lock switch  adjustment  Transmission 
brake drum - re-assemble. 
1. Select  differential  locked  position  by moving 1. Clean  brake backplate  and oil catcher  and 
the  lock  taper  towards 
the right  side of the  apply  sealant to the  catcher joint  face. 
transfer  box casing. 
2. Locate  brake  backplate  on the  rear  output 
2. Apply  sealant to the differential  lock warning  housing with the  brake  operating  lever  on the 
light  switch  and 
fit to the top  of the  front  right  side of the  transfer box casing. 
output  housing. 
3. Secure  the backplate  (including  the  oil 
3. Connect a test  lamp circuit to the  differential  catcher) with the four  special  bolts  and tighten 
lock  switch.  using  a hexagonal  socket 
to the  specified 
4. Screw  in the  lock  switch until the  bulb  is  torque. 
illuminated. 
4. Clean  and fit brake drum and secure  with two 
5. Turn in the switch  another  half a turn  and  countersunk screws. 
tighten  with  the  locknut against the housing. 
6.  Disconnect  the battery  and move  the 
differential  lock lever  to the  left to disengage 
differential  lock. 
7.  Clean  the front  output  housing  side cover. 
8.  Grease  and fit side  cover  gasket. 
9.  Apply  Loctite  290 to bolt  threads,  fit side  cover 
and  secure with  seven  bolts and washers.  
						

							PROPELLER SHAFTS 
OVERHAUL PROPELLER  SHAFTS 6. Remove paint, rust, etc. from  the  vicinity of 
Dismantle 
the universal joint  bearing  cups and circlips. 
NOTE: Before  dismantling  the  propeller shaft 
1. Remove the propeller  shaft from  the  vehicle. joint,  mark the position of the  spider  pin 
2. If a gaiter  encloses  the sliding  member lubricator  relative  to the  journal  yoke ears to 
release  the two  securing  clips. Slide the gaiter ensure  that the  grease  nipple  boss is 
along the shaft  to expose  the sliding  member. re-assembled  in the  correct  running  position  to 
3. Note  the  alignment  markings  on  the sliding reduce the  possibility of  imbalance. 
member  and  the propeller  shaft.  See NOTE 
following instruction 22. 7. Remove the circlips,  and  grease  nipple. 
4. Unscrew  the  dust  cap  and  withdraw  the 
sliding  member. 
8. Tap  the  yokes  to eject  the bearing  cups. 
9. Withdraw  the  bearing  cups and spider  and 
discard. 
10. Repeat  instructions 5 to 8 at opposite  end of 
propeller  shaft. 
11. Thoroughly  clean the  yokes  and bearing  cup 
locations. 
5. Clean  and examine the  splines for wear. Worn 
splines  or excessive back
-lash will  necessitate 
propeller 
shaft renewal.  
						

							PROPELLER SHAFTS 
Assemble 
12. Remove  the bearing  cups  from  the  new 
spider. 
13.  Check  that all needle  rollers are present  and 
are properly positioned  in the bearing  cups. 
14.  Ensure  bearing  cups  are  one third  full of fresh 
lubricant.  See 
RECOMMENDED 
LUBRICANTS
 . 
15. Enter  the new  spider  complete  with seals  into 
the  yokes 
of the  sliding  member flange. 
Ensure that  the  grease  nipple hole faces away 
from  the flange. 
16.  Partially  insert  one bearing  cup into a flange 
22. Lubricate  the  sliding  member spines  and 
fit 
yoke  and  enter  the spider  trunnion  into the  the sliding  member to the  propeller  shaft 
bearing  cup  taking  care  not to  dislodge  the  ensuring  that the markings  on both 
the sliding 
needle rollers.  member and  propeller  shaft align. 
17. Insert  the  opposite  bearing cup  into  the  flange 
yoke.  Using  a vice,  carefully  press both 
cups 
into place  taking  care to engage  the  spider 
trunnion  without dislodging  the needle  rollers. 
18. Remove  the flange  and spider  from  the vice. 
19. Using  a  flat faced  adaptor Of slightly  smaller 
diameter  than the bearing  cups press  each 
cup  into its  respective  yoke until they  reach 
the  lower  land  of the  circlip  grooves. 
Do not 
press  the  bearing  cups below  this point  or 
damage  may be caused 
to the  cups  and 
seals.  member.  NOTE: 
The 
Universal  joints on the  front  propeller 
shaft  are, by design,  not assembled  in
-line with 
one another.  Nevertheless,  the alignment  marks 
on  the  sliding  member  and propeller  shaft must 
coincide  when assembling. 
23. Fit  and  tighten the dust  cap. 
24. Fit the  grease  nipples to the spider  and  the 
sliding  member  and  lubricate. 
25. Slide  the gaiter (if fitted) over the sliding 
26.  Locate  the sliding  member  in the  mid
-position 
of  its  travel  and secure  the gaiter  clips. Note 
that  the gaiter clips  must be positioned  at 180° 
to  each  other  so that  they  will not influence 
propeller shaft  balance. 
20.  Fit the  circlips. 
21.  Engage  the spider  in the  yokes  of the  sliding 
member.  Fit  the  bearing  cups  and circlips  as 
described  in instructions  15 to 20. 
27. Apply  instructions  15 to 20  to  the  opposite 
end  of the  propeller  shaft. 
28.  Fit the  grease nipple  and lubricate. 
29.  Fit the  propeller  shaft to the  vehicle.  
						

							REAR AXLE AND FINAL  DRIVE 
REAR  HUBS 
REMOVE  AND OVERHAUL 
17. Clean  the hub  oil seal  housing  and ensure 
that  the seal  locating  surface 
is smooth and 
Special  tools: the chamfer  on the  leading  edge is also 
smooth  and free  from  burrs. 
Oil seal  replacer  L.R.T.-550-5 
Drift  for seal  replacer  M.S. 550 or 18G134 
18.  Examine  the new  seal  and ensure  that it is 
L.R.T.-99-003 clean,  undamaged  and that  the garter  spring 
Hub nut spanner  RO 606435A  L.R.T.54-002 is properly  located. Even a small  scratch  on 
the  seal 
lip could  impair  its efficiency. 
Remove 19.  Although  the new  seal  is already  pre-greased 
by  the  manufacturer,  apply one of the 
1.  Jack
-up the  vehicle,  lower onto axle stands  recommended hub bearing  greases to the 
and  remove  the road  wheels.  outside diameter  of the  seal,  before  fitting, 
2.  Remove 
the 
two brake drum retaining  screws  taking care not to damage  the lip. 
and  withdraw  the brake  drum. 
If necessary,  20. 
Place  the seal,  lip side  leading,  squarely on 
slacken  the brake  adjuster  to facilitate  the hub  and  using the 76 mm  end of seal 
removal.  replacer 
tool L.S.T.-550-5 
and  drift 550 or 18G 
134  drive  the seal  into position 
to the depth 
Fitting  inner oil seal 
3.  Prise-off the  hub  cap. 
4. Remove  the circlip.  determined by the  tool. 
5. Remove  the five  bolts  and withdraw  the hub 
driving  member  and joint  washer. 
6.  Prise
-up the  lock  washer  and remove  the 
outer  locknut  and inner  adjusting  nut. 
7. Withdraw  the hub  complete  with  with the inner 
and  outer  seals,  seal track  spacer,  and inner 
and  outer  taper  roller bearings. 
8. If the stub  axle is damaged  or scored  remove 
and  discard  it by  removing  the six brake  back 
plate  retaining  nuts and bolts. 
Fitting  outer oil seal 
21.  Fit the  new  outer  bearing  cone and pack  with 
one  of the  recommended  hub greases. 
22.  Carry  out instructions  17 
to 19 but insert  the 
seal  with the lip side  trailing. 
23.  Place  the seal,  lip side  leading,  squarely  on 
the  hub  and  using the 72 mm  end  of seal 
replacer  tool LS.T. 
550-5 and drift 550 or 18 
G 134, drive  the seal  into position to the 
depth  determined  by the  tool. 
Overhaul  hub 
9. Remove  the seal  track  spacer  and outer  seal. 
10. Remove  the outer  bearing  cone. 
11.  Remove  the inner  seal and bearing  cone.  24. 
Smear  the lips 
of both  seals  with one of the 
12. If new  bearings  are to be fitted  drift or press  recommended greases. This is important 
out  the  old cups.  since 
a dry  seal  can be destroyed  during the 
13.  Degrease 
and examine  the hub  for cracks  and  first few revolutions  of the  hub. 
damage  and renew 
if necessary.  Renew hub if 25. Select  a new  seal  track  spacer  and check  that 
wheel 
studs are  faulty.  the 
outer  diameter  is smooth  and free from 
blemishes  and that there  are no burrs  on the 
26.  Taking  care not 
to damage  the seal  lips fit the 
14. If removed,  fit the  stub  axle to the axle  casing  hub assembly  to the  stub  axle. Do not allow 
with  a new  joint  washer  and secure  with the  the weight  of the  hub 
to rest,  even 
six  nuts  and bolts  and tighten 
to the correct  temporarily, on the  outer  seal otherwise 
torque.  damage 
and distortion  could occur.  Therefore 
15.  Fit 
new  inner  and outer  bearing  cups to the  hold the hub  clear  of the  stub  axle until the 
hub,  ensuring  that they  are drifted 
or pressed  seal track  spacer is fitted. 
squarely  into position.  27. Carefully 
fit the seal  track  spacer,  seal lip 
16.  Fit the  inner  bearing  cone and pack  with one  leading. 
of the recommended  hub greases. 
Fitting  hub to stub  axle 
Assemble 
chamfered  leading edge.  
						

							REAR AXLE AND FINAL  DRIVE 
NOTE: Instruction 28 is applicable  to hubs  that 
have  been 
fitted with new components 
throughout.  If original  components  are being 
refitted  instruction  29 must 
be fallowed  using the 
adjustment 
nut to  achieve  the required  end-float. 
28. Fit the  hub  inner  nut and  using  wrench RO 
606435  tighten the adjusting  nut while  slowly 
revolving 
the hub  to  seat the bearings  and to 
remove  all end-float,  back-off the  nut 
approximately  half a 
turn and  retighten  the nut 
to 13-15 Ib in which  will automatically  allow for 
compression  of the  rubber  on the  new  seal 
track  spacer  giving the required  hub end
-float 
of  0.013 
to 0.10  mm. 
29. If the rubber  on the  seal  track  spacer  has 
previously  been compressed  the hub  end
-float 
can  be checked  by mounting  a dial  indicator 
and  bracket  on the  hub 
so that  the trace  pin 
rests 
in a  preloaded  condition on the  nut. 
Rotate  the hub 
to settle  the bearings  and 
check  the end
-float  by pushing  and pulling  the 
hub.  End
-float must  fall within  the limits  given 
in  the  previous  instruction. 
30.  Fit a new  lock  washer  and locknut. 
Restraining  the inner  adjustment  nut, tighten 
the  outer  lock  nut to 
95 to 108 Nm. 
31. 
If original  components  have been refitted 
rotate  the hub  several  times to settle  the 
bearings  then recheck  the end
-float,  refer to 
previous  note and instruction 
29. 
32.  Bend  one segment  of the  locker  washer  over 
the  adjusting  nut and  another,  diametrically 
opposite,  over the locknut. 
33.  Using  a new  joint  washer, 
fit the hub  driving 
member  and secure  with the five  bolts  and 
tighten  evenly 
to the correct  torque. 
34. 
Fit the  circlip  to the  axle  shaft  ensuring  that it 
is  properly  seated 
in the groove. 
35.  Fit the  hub 
cap. 
36.  Fit the road wheels and secure with the nuts. 
Jack
-up  the  vehicle,  remove axle stands  and 
lower vehicle to ground. Finally tighten  the 
road  wheel  nuts to 
the correct  torque.  
						

							REAR AXLE AND FINAL DRIVE 
KEY TO REAR HUB COMPONENTS 
1.  Hubcap.  14. Locknut 
3.  Spring  washer.  hub driving  member  bolt.  15. Locknut. 
4.  Hub  driving  member.  16. 
Axle shaft 
5.  Hub  driving  member  bolts.  17. 
Locknut. 
6.  Brake  drum retaining  screws.  18. 
Lock washer. 
7.  Outer  bearing  cone.  19. 
Joint washer. 
9.  Inner  bearing  cup.  21. 
Hub casting. 
10.  Inner  bearing  cone. 
11.  End
-float adjusting  nut.  23. Outer  oil seal. 
12.  Inner  oil seal.  24. Road  wheel  stud. 
2. 
Circlip.  15. Bolt. 
8.  Outer  bearing  cup.  20. Seal track  spacer.  I 
22.  Brake  drum. 
13.  Joint  washer,  25. Stub axle.