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 action/operation ofmain selector railand
forks.
5. Check condition ofsynchromesh andgear dog
teeth.
6. Check mainandlayshaft endfloats bearings and
adjustments.
7. Check condition ofall gearbox components,
ensure clearances andadjustments arecorrect
on reassembly.
Symptom -Reverse gearonlyjumps outof
engagment
1. Check condition andsecurity oftransmission
and engine mountings.
2. Check insitu, gear lever andselector
adjustments
See Adjustment, Gearchange
lever biasspring adjust
andSeeAdjustment,
Fifth gearstopscrew adjust
.
3. Insitu, remove gearshift andcheck selector rail
yoke security.
Also check selector detentspringtension and
both spool retainers.
Suspect internalfault,seeOverhaul Manual.
4. Check action/operation ofmain selector railand
reverse lever.
5. Check condition ofreverse gear,angled
bearings andshaft.
6. Check condition ofall gearbox components,
ensure clearances andadjustments arecorrect
on reassembly. Symptom
-Excessive forcerequired toengage or
change gear,vehicle stationary ormoving.
1. Check lubricant specification andlevel, iflow do
not topupatthis stage.
2. Insitu, lubricate gearmechanism, andcheck
selector adjustments
SeeAdjustment, Gear
change leverbiasspring -adjust
andSee
Adjustment, Fifthgearstopscrew adjust
.
3. Insitu, remove gearshift andcheck selector rail
is free andthattheyoke issecure. Alsocheck
selector detentspringtension andboth spool
retainers.
4. Drain lubricant andcheck forcontamination or
metal particles.
Suspect wornsynchromesh unitorbaulk rings
on affected gears,seeOverhaul Manual.
Symptom -Noisy gearengagement, vehicle
stationary
See CLUTCH, Faultdiagnosis, Clutch
Noise -Mechanical Faults
.
Symptom -Noisy gearselection, vehiclemoving.
1. Confirm thatclutch operation issatisfactory.
2. Establish whichgear/gears iscausing noise.
3. Check lubricant specification andlevel, iflow do
not topupatthis stage.
4. Drain lubricant andcheck forcontamination or
metal particles.
Suspect wornsynchromesh, seeOverhaul
Manual.
5. Check condition ofsynchromesh unit,springs
and cones fordistortion andwear. Alsocheck
dog teeth fordamage andcone mating surface
on gear forsigns ofoverheating.
6. Check condition ofall gearbox components,
ensure clearances andadjustments arecorrect
on reassembly.
Symptom -Noise fromgearbox inneutral, which
changes toneorbecomes worsewhenclutch is
depressed,
See CLUTCH, Faultdiagnosis, Clutch
Noise -Mechanical Faults
.
Symptom -Noise fromgearbox inneutral, which
disappears whenclutch isdepressed.
1. Check lubricant specification andlevel, iflow do
not topupatthis stage.
2. Drain lubricant andcheck forcontamination or
metal particles.
Suspect wornbearings onlayshaft, primaryshaft
or front ofmain shaft, seeOverhaul Manual.  
						

							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. Apply aslight loadtogear lever inaLH direction
and adjust RHscrew downward untilRHspring
leg just makes contact withcross pin.
10. Repeat procedure forLH adjustment screw.
11. Lower bothadjustment screwsequalamounts
until radial playiseliminated.
12. Tighten locknuts.
13. Return gearlever toneutral position androck
across gateseveral times.Thegear lever should
return to3rd and 4thgate.
14. Remove gearlever.
15. Fitinsulation pad.
16. Locate gaiteroverlower leverandbias springs.
17. Fitgear lever tolower leverspline, secure with
new nyloc nutand tighten to
25Nm (18lbf/ft).
18. Fitgear lever cover.
19. Fitgear lever andtransfer boxlever knobs.     
						

							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 tunnelcoverto
vehicle body.
10. Manouvre tunnelcovertoclear handbrake lever
and remove fromvehicle.
11. Fitgear lever andknob andselect reverse gear.     
						

							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.
22. Locate gaiteroverlower leverandbias springs.
23. Fitgear lever tolower leverspline, secure with
new nyloc nutand tighten to
25Nm (18lbf/ft).
24. Fitgear lever cover.
25. Fitgear lever andtransfer boxlever knobs.   
						

							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 necessary toremove theundertray
See
CHASSIS ANDBODY, Repair, Frontundertray
or
SeeCHASSIS ANDBODY, Repair, Rearundertray
.
1. Install vehicle onaramp.
2. Disconnect battery.
3. Remove gearboxcarpet.
4. Remove gearlever andtransfer boxlever knobs.
5. Remove gearlever cover.
6. Remove nutand washer securing gearlever.
7. Mark gearlever spline setting andremove lever
and gaiter fromthesplined lowergearlever.
8. Release insulation padfrom tunnel coverand
gear levers andremove.
9. Select lowrange ontransfer boxlever toprevent
lever fromfouling tunnelwhenremoving gearbox     
						

							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 system is
fitted, slacken 2retaining clipsanddisconnect
intake hoseatintercooler.
16. Slacken retaining clipand disconnect hoseat
turbocharger.
17. Remove boltsecuring transmission breather
pipe cliptorear ofengine.
18. Release breather pipes.
19. Release tiessecuring gearboxharnessto
breather pipes.
20. Raise vehicle onramp.
21. Position asuitable container undertransmission
and drain maingearbox andtransfer box
See
SECTION 10,Maintenance, Undervehicle
maintenance
.
22. Mark frontpropeller shaftdriveflange and
transfer boxoutput flangeforreassembly.
23. Remove 4nuts anddisconnect propellershaft
from transfer box.     
						

							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 SYSTEM,Repair,
Intermediate pipe-110/130
29. Temporarily supporttransmission.
30. Remove nutsecuring gearboxLHmounting
rubber tochassis crossmember.
31. Remove 4nuts andbolts securing crossmember
to chassis longitudinals.
32. Remove nutsecuring transferboxmounting
rubber toRH side ofcrossmember.
33. Remove 4nuts andbolts securing crossmember
to chassis longitudinals.
34. With assistance andusing abody jackbetween
chassis longitudinals, jackchassis sufficiently to
enable removal ofcrossmember.
35. Remove chassscrossmember.
36. Remove 4bolts frombothsides andremove LH
and RHmounting brackets.      
						

							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 transmission tunnelaperture.
44.Disconnect differentiallockswitch andreverse
light connectors.
45.Remove boltand release earthleads fromRH
side oftransfer box.
46.Support engineundersumpwithajack.
47. Remove 14bell housing toengine fixings.
48. Withdraw transmission whilstensuring all
connections toengine andchassis arereleased.
49. Lower hoistandremove gearbox assembly.       
						

							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
gearbox toextension housing.
58. Withdraw transfergearbox.
Assembling transfergearbox tomain gearbox
59. Clean extension housingandtransfer gearbox
mating faces.
60. Ensuring looseupper dowel isfitted, hoist
transfer gearbox intoposition.
61. Secure transfer boxtoextension housing.
Tighten fixingsto
40Nm (30lbf/ft).
62. Connect high/lowoperating rod,fitand tighten
locknut.
63. Fitlink todifferential locklever andsecure with2
clips
64. Align levertohigh/low shaft,position washer, fit
bolt and new Nyloc nut.Tighten to
2Nm (1.5
lbf/ft).
65. Position breather pipes,secure pipeunions
using newsealing washers. Tightenunionsto
15
Nm (11lbf/ft).
Fitting transfer gearbox andmain gearbox
assembly
66. Position transmission assemblytohoist cradle.
67. Clean bellhousing andengine matingfaces.
Apply sealant toboth mating faces.
68. Temporarily fitgear lever andselect anygear in
main gearbox tofacilitate entryofgearbox input
shaft. Engage lowrange.
69. Position andraise hoist, fittransmission to
engine whilstkeeping harness andpipes clearto
prevent trapping.
70. Secure transmission toengine. Tighten fixingsto
45Nm (33lbf/ft).
71. Secure earthleads toRH side oftransfer box.
72. Connect reverselampswitch connectors and
differential lockswitch connectors.
73. Secure breather pipestoharness withclips.
74. Remove supportfromengine sump.
75. Position temporary supportundertransmission.
76. Secure LHand RHmounting bracketsto
gearbox. Tightenfixingsto
55Nm (41lbf/ft).
77. With assistance andusing abody jackbetween
chassis longitudinals, jackchassis sufficiently to
enable fitmentofcrossmember.