Land Rover Defender Workshop Rover Manual

MANUALGEARBOX
1
FAULT
DIAGNOSIS
R380
GEARBOX
Symptom -Gear jumps outofengagement (any
forward gear)
1. Check condition andsecurity oftransmission
and engine mountings.
2. Check insitu, gear lever andselector
adjustments
See Adjustment, Gearchange
lever biasspring -adjust
andSee
Adjustment, Fifthgearstopscrew adjust
.
3. Insitu, remove gearshift andcheck selector rail
yoke security.
Also check selector detentspringtension and
both spool retainers.
Suspect internalfault,seeOverhaul Manual.
4. Check...

37MANUAL
GEARBOX
2 FAULT
DIAGNOSIS
Symptom
-Noise fromgearbox inone ormore
gears whenbeing driven.
1. Check lubricant specification andlevel, iflow do
not topupatthis stage.
2. Drain lubricant andcheck forcontamination or
metal particles.
Suspect wornroller bearings onparticular
mainshaft gears,seeOverhaul Manual. 

MANUALGEARBOX
1
ADJUSTMENT
GEAR
CHANGE LEVERBIASSPRING -ADJUST
Service repairno-37.16.26
1. Remove gearlever andtransfer boxlever knobs.
2. Remove gearlever cover.
3. Remove nutand washer securing gearlever.
4. Mark gearlever spline setting, remove leverand
gaiter fromlower lever.
5. Remove insulation padfrom tunnel aperture.
6. Fitgear lever andselect 3rdor4th gear.
7. Slacken adjustment screwlocknuts.
8. Adjust screws untilboth legsofbias springs are
approximately 0.5mmclearofgear lever cross
pin.
9....

37MANUAL
GEARBOX
2 ADJUSTMENT
FIFTH
GEAR STOPSCREW -ADJUST
Service repairno-37.16.67
1. Remove gearlever andtransfer boxlever knobs.
2. Remove gearlever cover.
3.Remove nutand washer securing gearlever.
4. Mark gearlever spline setting, remove leverand
gaiter fromlower lever.
5. Remove insulation padfrom tunnel aperture.
6. Remove tunnelcarpet.
7.Remove retaining screwsandrelease fusebox
cover.
8. Remove 2screws andrelease fuseboxfrom
bulkhead toassist nextoperation.
9.Remove 16screws securing...

MANUALGEARBOX
3
ADJUSTMENT
12.
Slacken stopscrew locknut.
13. Apply lightpressure togear lever towards LH
side andturn screw clockwise untilitabuts yoke.
14. Turn screw anti-clockwise until25mm freeplay
is felt atgear lever knob. Ensure 5thgear canbe
engaged.
15. Tighten stopscrew locknut.
16. Check thatallother gears areselectable.
17. Remove gearlever.
18. Manouvre tunnelcoverintoposition andsecure
with 16screws.
19. Fitfuse boxand cover.
20. Fittunnel carpet.
21. Fitinsulation padintotunnel aperture....

MANUALGEARBOX
1
REPAIR
R380
GEARBOX
Service repairno-37.20.51
Remove The R380 gearbox shouldberemoved from
underneath thevehicle, usingahydraulic hoistand
support plateLRT-99-007 .
WARNING: Wheretheuse ofa
transmission hoistisnecessary, itis
absolutely essentialtofollow the
manufacturers instructionstoensure safeand
effective useofequipment.
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures arerequired, itmay
be...

37MANUAL
GEARBOX
2 REPAIR
10.
Remove 3trim studs andliftup handbrake
gaiter.
11. Remove splitpin,clevis pin,washer and
disconnect cablefromhandbrake lever.Ensure
handbrake isoff.
12. Drain cooling system
SeeCOOLING SYSTEM,
Adjustment, Drainandrefill cooling system
.
13. Remove viscousfanunit
See COOLING
SYSTEM, Repair,Viscous coupling andfan
.
14.Slacken retaining clipand disconnect radiator
top hose atthermostat housing.
15. Slacken retaining clipand disconnect intake
hose atinduction manifold. IfEGR...

MANUALGEARBOX
3
REPAIR
24.
Remove 2bolts, withdraw clutchslavecylinder
and backing platefrombellhousing, andtie
aside.
25. Mark rearpropeller shaftdriveflange and
transmission brakedrumforreassembly.
26. Remove 4nuts, disconnect propellershaftfrom
brake drum, andtieaside.
27. Remove frontpipefrom exhaust manifold
See
MANIFOLD ANDEXHAUST SYSTEM,Repair,
Exhaust frontpipe
.
28. Remove intermediate silencer.
SeeMANIFOLD
AND EXHAUST SYSTEM,Repair,
Intermediate pipe-90
orSee MANIFOLD
AND EXHAUST...

37MANUAL
GEARBOX
4 REPAIR
37.
Pullhandbrake cablethrough heelboard andtie
aside.
38. Remove retaining nut,release clamp,and
disconnect speedometer cablefromtransfer box.
39. Release speedometer cablefromretaining clip
on transfer box.
40. Remove retaining nutand release batteryearth
strap fromtransfer box.
41.Secure manufactured cradleLRT-99-007 toa
suitable hydraulic hoist.
42. Raise hoistandsecure togearbox with3bolts in
location provided.
43. Lower hoistsufficiently toallow transfer leverto
clear...

MANUALGEARBOX
5
REPAIR
Separating
transfergearbox frommain gearbox
50. Remove transmission assemblyfromhoist
cradle andposition safelyonabench.
51. Remove breatherpipes.Discard pipeunion
sealing washers.
52. Remove Nylocnut,and remove bolt,securing
lever tohigh/low shaft.
53. Collect spacerwasher.
54. Remove 2clips andremove differential lock
lever link.
55. Remove lowerlocknut fromhigh/low operating
rod.
56. Place asling round transfer boxand attach to
hoist.
57. Remove nutand 4bolts securing transfer...