Land Rover Defender Workshop Rover Manual

37MANUAL
GEARBOX
6 REPAIR
78.
Position crossmember andlocate overfixing
studs ofLH and RHgearbox mounting rubbers.
79. Align crossmember andsecure tochassis with4
nuts andbolts oneach side.
NOTE: Fitbattery earthstrapretaing clip
to LH top bolt.
80. Fitintermediate silencer.
SeeMANIFOLD AND
EXHAUST SYSTEM,Repair,Intermediate
pipe -90
orSee MANIFOLD ANDEXHAUST
SYSTEM, Repair,Intermediate pipe-110/130
.
81. Fitfront pipetoexhaust manifold
See
MANIFOLD ANDEXHAUST SYSTEM,Repair,
Exhaust frontpipe
.
82....

MANUALGEARBOX
1
SPECIFICATIONS,
TORQUE
TORQUE
VALUES
NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are
tightened tothe correct torque.
Nm
Slave cylinder tobell housing 25
....................................................................
Breather 15
.....................................................................................................
Bell housing tocylinder block 40
.....................................................................
High/low...

TRANSFERGEARBOX
1
DESCRIPTION
ANDOPERATION
TRANSFER
GEARBOX
Description The transfer gearbox isapermanent 4wheel drive,
two speed ratioreducing gearbox, incorporating high
and lowrange outputs withmechanically lockable
centre differential (diff-lock).High/lowrangeand
diff-lock selection aremade viaasingle leverlocated
forward ofthe main gearlever.
The transfer gearbox ismounted atthe rear ofthe
main gearbox, themainshaft ofwhich extends intothe
transfer casing.Atransfer gear,supported ontaper
roller...

TRANSFERGEARBOX
1
FAULT
DIAGNOSIS
TRANSFER
GEARBOX-OIL SEAL LOCATIONS
1.Input seal.
2. Cover platejoints.
3. Front output seal.
4. Front andrear housing jointfaces. 5.
Rear output seal.
6. Power takeoffcover platejoint.
7. Bearing platejoint.   

41TRANSFER
GEARBOX
2 FAULT
DIAGNOSIS
OIL
LEAKS
Verify thatoilleak isfrom transfer boxand notmain
gearbox beforeproceeding withchecks.
Prior toroad test
1. Check oillevel intransfer boxiscorrect.
2. Check tightness oflevel anddrain plugs.
3. Check breather systemforblockage. Tovalidate
system pipemust beremoved, inspected,
rectified asnecessary andrefitted.
4. Remove alltraces ofoil from exterior oftransfer
box.
Take vehicle forshort roadtest.
5. Identify sourceofleaks andrectify asfollows.
Front orrear...

TRANSFERGEARBOX
1
REPAIR
TRANSFER
GEARBOX
Service repairno-41.20.25
Remove The transfer gearbox shouldberemoved from
underneath thevehicle, usingahydraulic hoistand
adaptor plateLRT-99-010 .
WARNING: Whereuseofatransmission
hoist isnecessary, itis absolutely
essential tofollow themanufacturers
instructions toensure safeandeffective useof
the equipment.
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures...

41TRANSFER
GEARBOX
2 REPAIR
11.
Remove 3trim studs andliftup handbrake
gaiter.
12. Remove splitpin,clevis pin,washer and
disconnect cablefromhandbrake lever.Ensure
handbrake isoff.
13. Release handbrake outercable fromheelboard.
14. Remove fancowl
See COOLING SYSTEM,
Repair, Fancowl
.
15. Raise vehicle onramp.
16. Drain transfer boxoil
See SECTION 10,
Maintenance, Undervehicle maintenance
.
17. Remove intermediate silencer.
SeeMANIFOLD
AND EXHAUST SYSTEM,Repair,
Intermediate pipe-90
orSee MANIFOLD
AND...

TRANSFERGEARBOX
3
REPAIR
23.
Position 4,30 mm (1.25 in),spacers between
top ofhoist andadaptor plate,LRT-99-010 ,at
securing pointsandsecure adaptor plateto
hoist.
24. Remove 4central boltsfromtransfer boxbottom
cover, movehoistintoposition andsecure
adaptor platetotransfer box.
25. Adjust hoisttotake weight oftransfer box.
26.Remove nutsecuring transferboxLHmounting
rubber tochassis crossmember.
27. Remove 4nuts andbolts securing chassis
crossmember tochassis longitudinal.
28. Remove nutsecuring...

41TRANSFER
GEARBOX
4 REPAIR
36.
Remove retaining nut,release clamp,and
disconnect speedometer cablefromtransfer
gearbox.
37. Remove batteryearthstrapretaining nut,1nut
and 4bolts, securing transferboxtomain
gearbox extension case.
38.Remove retaining nutsecuring earthleads toRH
side oftransfer box.
39. Fitthree guide studs, LRT-41-009 ,through
transfer boxboltholes tosupport itduring
removal.
40. Lower hoistandwithdraw transferboxfrom main
gearbox.
41. Remove transferbox. Refit
42. Ensure jointfaces...

TRANSFERGEARBOX
5
REPAIR
63.
Feed transmission brakecablethrough heel
board. Ensure cablegrommet iscorrectly
located.
NOTE: Applyasoap solution toaid fitment
of cable.
64. Lower vehicle ramp.
65. Connect cableclevis tohandbrake leverandfit
handbrake gaiter.
66. Connect high/lowlevertooperating rod.
67. Fitbreather pipebanjo uniontohigh/low
cross-shaft housing.
68. Fitcntre access paneltoseat base. Iffitted,
secure EGRandalarm system diagnostic
connector mountingbrackettofront ofaccess
panel.
69....