Land Rover Defender Workshop Rover Manual
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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. Fitrear propeller shafttotransmission brake drum. Tighten nutsto 47Nm (33lbf/ft). 83. Remove 3bolts securing supportcradleto transmission andremove hoist. 84. Reconnect batteryearthstraptotransfer box fixing. 85. Connect speedometer cabletotransfer boxand secure withretaining clip. 86. Coat bothsides ofclutch slaveclinder backing plate withHylomar P232Mwaterproof sealant. 87. Locate backing plateonslave cylinder. 88. Fitslave cylinder tobell housing, engaging push-rod throughcentreofdust cover, andwith bleed screw uppermost. Tightenboltsto 25Nm (18 lbf/ft). 89. Fitfront propeller shafttotransfer box.Tighten nuts to 47Nm (33lbf/ft). 90. Refill maingearbox andtransfer boxSee SECTION 10,Maintenance, Undervehicle maintenance . 91. Feed transmission brakecablethrough heel board andensure grommet iscorrectly located. NOTE:Applyasoap solution toaid fitment of cable. 92. Lower vehicle onramp. 93. Fitties tosecure gearbox harnessto transmission breatherpipes. 94. Fitbreather piperetaining cliptorear ofengine. 95. Reconnect chargeairhose atturbocharger. 96. Reconnect intakehoseatinduction manifold. If EGR system isfitted, reconnect intakehoseat intercooler. 97. Reconnect radiatortophose atthermostat housing. 98. Fitviscous fanunit See COOLING SYSTEM, Repair, Viscous coupling andfan . 99. Reconnect battery. 100. Refill cooling system SeeCOOLING SYSTEM, Adjustment, Drainandrefill cooling system . 101. Connect cableclevis tohandbrake leverandfit handbrake gaiter. 102. Locate insulation padover gear levers andfitto tunnel cover. 103. Fitgear lever withgaiter tolower leverspline and secure withretaining nut. 104. Fitgear lever cover. 105. Fitgear lever andtransfer boxlever knobs. 106. Fitgearbox covercarpet. 107. Check operation ofhandbrake andadjust as necessary See SECTION 10,Maintenance, Under vehicle maintenance .
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 leveltoshaft 2 ................................................................................. Transfer boxtogearbox 45 ............................................................................. NOTE: Torque valuesbelowapplytoall screws andbolts usedunless otherwise specified. METRIC Nm M5 6 ...................................................................................................... M6 9 ...................................................................................................... M8 25 ..................................................................................................... M10 45 ................................................................................................... M12 90 ................................................................................................... M14 105 .................................................................................................. M16 180 .................................................................................................. UNC /UNF 1/4 9 ...................................................................................................... 5/16 24 ................................................................................................... 3/8 39 ..................................................................................................... 7/16 78 ................................................................................................... 1/2 90 ..................................................................................................... 5/8 136 ....................................................................................................
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 bearings andsplined tothe gearbox mainshaft, passes thedrive toan intermediate gearcluster supported onasingle shaftandrotating ontaper roller bearings. The intermediate gearspassthedrive tohigh andlow speed gearsonthe rear output shaft.Therear output shaft passes through thespeedo drivehousing, which also forms themounting forthe transmission brake.A worm gearfitted tothe rear output shaftdrives a pinion fittedinthe speedo housing. Integral withtheoutput shaftsisadifferential assembly whichcompensates forspeed differences between thefront andrear prop shafts. Toprevent all the power beingtransmitted tothe axle offering the least resistance, adiff-lock isprovided. Thedifferential lock should onlybeengaged duringsevere off-road conditions andshould bedisengaged assoon as conditions permit.Selection ofdifferential lock engages, throughmechanical linkage,adog clutch with thefront output shaft,thisaction locksthecentre differential andprovides afixed drive, giving equal power tothe front andrear output shafts.
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 output sealleaking:- 1. Drain oiland remove leakingoutputflange. 2. Inspect sealtrack onflange forsurface damage. If damaged renewcomponent. 3. Remove anddiscard oilseal. 4. Inspect seallocating boreandremove anysharp edges whichmaydamage newoilseal. 5. Fitnew seal. 6. Fitoutput flangeandallother parts. 7. Add oiltocorrect levelintogearbox See SECTION 10,Maintenance, Undervehicle maintenance . Cover platesealant leaking. 1. Drain oiland remove leakingcoverplate. 2. Remove alltraces ofjoint sealant frombothjoint faces. 3. Degrease allcomponents andapply athin filmof Hylomar sealant,toboth jointfaces. 4. Apply thread sealant tobolts which comeinto contact withgearbox oil. 5. Refit cover plate. CAUTION: Caremust betaken notto overtighten fixings. Leak between mainandtransfer gearboxes. 1. Site vehicle ontoaramp . 2. Select neutral intransfer boxand select 4thgear in main gearbox. 3. Run engine at2000 rpmwith clutch/drive engaged. 4. Observe jointbetween mainandtransfer boxes. 5. Ifoil leak isfound establish ifitis gear oil. 6. Ifso, leak isoriginating fromtransfer box. 7. Check twoinner (main/transfer) boltsareoil tight, asthese holesaretapped intomain transfer case. 8. Remove transferboxtoinspect mainshaft collar seal track condition, andfront faceoftransfer case forporosity See Repair, Transfer gearbox . 9. Ifthese areas require servicing, transfergearbox input sealmust alsoberenewed. CAUTION: Avoiddamaging newseallip and ensure sealisfitted flushwith machined face.Alsoensure newsealis not damaged whenrefitting transfer gearbox. 10. Ifred ATF typeoilisseen leaking during workshop test,investigate maingearbox for cause ofleak. Detent plugorelectrical switchleaks. 1. Detent plugsandelectrical switchesdonot usually leak.Itmust benoted thatthey fitinto open tapped holesintransfer caseandtherefore should beconsidered whenlooking forsource of leak.
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 arerequired, itmay be necessary toremove theundertray See CHASSIS ANDBODY, Repair, Frontundertray or SeeCHASSIS ANDBODY, Repair, Rearundertray . 1. Position vehicleonaramp. 2. Select LOWrange gearandleave vehicle in neutral. 3. Disconnect battery. 4. Remove front,centre, seatcushion, orcubby box See CHASSIS ANDBODY, Repair, Cubby box . 5. Iffitted, disconnect multi-plugfromEGR control unit located onbase ofseat cushion orcubby box. 6. Remove 4screws securing centreaccess panel to seat orcubby boxbase. 7. Release EGRandalarm system diagnostic connector mountingbracket. 8. Lift upaccess panel,complete withdiagnostic connector harness,andplace aside. 9.Remove breatherpipeunion fromtransfer gearbox high/low cross-shaft housing. 10. Remove retaining clipand disconnect high/low lever fromoperating rod.
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 EXHAUST SYSTEM,Repair, Intermediate pipe-110/130 . 18. Mark rearpropeller shaftdriveflange and transmission brakedrumforreassembly. 19. Remove 4nuts, disconnect propellershaftfrom brake drum, andtieaside. 20. Mark frontpropeller shaftdriveflange and transfer boxoutput flangeforreassembly. 21. Remove 4nuts, disconnect propellershaftfrom transfer box,andtieaside. 22. Remove retaining clipatlower endofpivot arm and disconnect differentiallockcontrol operating rod.
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 transferboxRHmounting rubber tochassis crossmember. 29. Remove 4nuts andbolts securing chassis crossmember tochassis longitudinal. 30. With assistance andusing abody jackbetween chassis longitudinals, jackchassis sufficiently to enable removal ofcrossmember. 31. Remove chassiscrossmember. 32. Remove 4bolts frombothsides andremove LH and RHmounting bracketsfromtransfer box. 33.Disconnect electricalleadsfromdifferential lock switch. 34. Move thesmall cranked lever,forhigh/low selector, upwardtoallow access toadjacent nut securing transferboxtomain gearbox. 35. Position ajack tosupport maingearbox. CAUTION: Useablock ofwood orhard rubber padtoprotect gearbox.
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 oftransfer boxand main gearbox areclean andguide studs, LRT-41-009 , are fitted toextension case. 43. Lubricate oilseal injoint face oftransfer box. 44. Secure transfer boxtoadaptor plateonlifting hoist andraise hoistuntiltransfer boxcanbe located overguide studs. 45. Remove guidestuds, fitbattery earthstrap, and secure transfer boxtomain gearbox extension case. Tighten fixingsto 45Nm (33lbf/ft). 46. Fitelectrical leadstodifferential lockswitch. 47. Raise hoistandremove wooden block supporting maingearbox. 48. Secure LHand RHmounting bracketsto gearbox andtighten fixingsto 55Nm (41lbf/ft). 49. With assistance andusing abody jackbetween chassis longitudinals, jackchassis sufficiently to enable fitmentofcrossmember. 50. Position chassiscrossmember andlocate over fixing studs ofLH and RHgearbox mounting rubbers . 51. Align crossmember andsecure tochassis with4 nuts andbolts oneach side. NOTE: Fitbattery earthstrapretaining clip to LH top bolt. 52. Remove bodyjack. 53. Fitretaining nuttoLH and RHmounting rubbers. Tighten to 21Nm (15lbf/ft). 54. Remove 4bolts securing hoistadaptor plateto transfer boxbottom cover. 55. Lower hoistandmove aside. 56. Clean threads ofthe 4bolts, coatwithLoctite 290, andfitto transfer boxbottom cover.Tighten to 25 Nm (18lbf/ft). 57. Fitearth leads toRH side oftransfer box. 58. Connect differential lockcontrol operating rodto pivot arm. 59. Fitspeedometer cabletotransfer box. 60. Fitfront andrear propeller shaftstotransfer box. Tighten nutsto 47Nm (33lbf/ft). 61. Fitintermediate silencer.SeeMANIFOLD AND EXHAUST SYSTEM,Repair,Intermediate silencer -90; Refit orSee MANIFOLD AND EXHAUST SYSTEM,Repair,Intermediate pipe -110/130; Refit . 62. Refill transfer boxwith recommended oil See SECTION 10,Maintenance, Undervehicle maintenance
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. Iffitted, reconnect multi-plugtoEGR control unit on base ofcentre seatcushion orcubby box. 70. Fitseat cushion orcubby box SeeCHASSIS AND BODY, Repair, Cubbybox . 71. Reconnect battery. 72. Check operation ofhandbrake andadjust as necessary See BRAKES, Repair,Handbrake cable .