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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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TRANSFER BOX REPAIRS 41-3 REPAIRS Transfer gearbox - Td6 $% 41.20.25.99 Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. + GENERAL INFORMATION, Electrical Precautions. Remove 1.Position vehicle on lift. 2.Disconnect battery earth lead. 3.Remove engine cover. + ENGINE - Td6, REPAIRS, Cover - engine access. 4.Remove viscous coupling. + COOLING SYSTEM - Td6, REPAIR, Coupling unit - viscous fan. 5.Raise vehicle on lift. 6.Drain transfer gearbox oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. 7.Remove rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 8.Remove front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 9.Remove 5 nuts, release and remove RH heat shield. 10.Support gearbox on a jack.11.Remove nut and bolt securing mounting to cross member. 12.Remove 6 bolts securing cross member and remove cross member. 13.Remove snubbers from mounting. 14.Lower gearbox on jack. CAUTION: Do not allow gearbox to hang on gear selector cable. M41 7828
TRANSFER BOX 41-4 REPAIRS 15.Disconnect multiplug from high/low shift motor. 16.Disconnect breather hose from gearbox. CAUTION: Always fit plugs to open connections to prevent contamination. 17.Support transfer gearbox on jack. 18.Remove 9 Torx bolts and remove transfer gearbox. NOTE: Do not carry out further dismantling if component is removed for access only. 19.Remove 3 Torx screws securing mass damper and remove damper.20.Lubricate centre screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown to remove mounting from transfer gearbox. CAUTION: Ensure tool alignment indicator is at the 6 oclock position. The tool alignment indicator is a machined flat on LRT-41-018/1 and LRT-41-018/2. Refit 1.Clean mounting and mating faces. 2.Lubricate new mounting and bore in transfer gearbox casing to aid assembly. M41 7829M12 7539A LRT-41-018/2LRT-41-018/1 LRT-41-018/4
TRANSFER BOX REPAIRS 41-5 3.Position new mounting to rear face of transfer gearbox, and start entry. Mounting to be parallel, with timing marks aligned. NOTE: Transfer timing mark to side of mounting to assist with alignment. 4.Lubricate centre screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown, to fit mounting to transfer gearbox. Start with the centre screw at full length and when the mounting is approximately 75 percent fitted, reduce the length of the centre screw by screwing it fully into the base plate LRT-41-018/1. This will ensure the centre screw LRT-41-018/4 does not foul on the gearbox fluid pan. CAUTION: Ensure tool alignment indicator is at the 6 oclock position. 5.Ensure the mounting is fitted parallel. If necessary, use a mallet and tap the base plate to maintain a parallel fit. 6.Clean damper and mating face. 7.Fit damper and tighten Torx screws to 23 Nm (17 lbf.ft). 8.Clean transfer gearbox and mating face dowels and dowel holes.9.Clean input shaft and mating face. 10.Apply thin coat of anti-seize grease to shaft splines. 11.Fit transfer gearbox and tighten Torx bolts to 43 Nm (32 lbf.ft). 12.Connect breather hose to gearbox. 13.Connect multiplug. 14.Remove support from transfer gearbox. 15.Fit snubbers. 16.Fit cross member to mounting, fit nut and bolt but do not tighten at this stage. 17.Raise gearbox on jack. 18.Align cross member, fit bolts and tighten to 68 Nm (50 lbf.ft). 19.Remove support from gearbox. 20.Tighten nut and bolt securing mounting to cross member to 100 Nm (74 lbf.ft). 21.Fit heat shield and secure with nuts. 22.Fit rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 23.Fit front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 24.Refill transfer gearbox with oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. 25.Fit viscous coupling. + COOLING SYSTEM - Td6, REPAIR, Coupling unit - viscous fan. 26.Fit engine cover. + ENGINE - Td6, REPAIRS, Cover - engine access. M12 7540A LRT-41-018/4 LRT-41-018/3 LRT-41-018/1
TRANSFER BOX 41-6 REPAIRS Transfer gearbox - V8 $% 41.20.25.99 Remove 1.Position vehicle on lift. 2.Disconnect battery earth lead. 3.Use LRT-12-214 and LRT-12-215 to loosen viscous coupling lock nut and remove fan assembly from coolant pump. NOTE: Thread is left handed. 4.Raise vehicle on lift. 5.Drain transfer gearbox oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. 6.Remove rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 7.Remove front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 8.Remove 5 nuts, release and remove RH heat shield. 9.Support gearbox on a jack.10.Remove nut and bolt securing mounting to cross member. 11.Remove 6 bolts securing cross member and remove cross member. 12.Remove snubbers from mounting. 13.Lower gearbox on jack. CAUTION: Do not allow gearbox to hang on gear selector cable. M41 7828
TRANSFER BOX REPAIRS 41-7 14.Disconnect multiplug from high/low shift motor. 15.Disconnect breather hose from gearbox. CAUTION: Always fit plugs to open connections to prevent contamination. 16.Release clips securing oxygen sensor leads to transfer gearbox. 17.Support transfer gearbox on jack.18.Remove 9 Torx bolts and remove transfer gearbox. NOTE: Do not carry out further dismantling if component is removed for access only. 19.Remove 4 bolts securing oxygen sensor multiplug retaining brackets from transfer gearbox. M41 7829 M41 7834
TRANSFER BOX 41-8 REPAIRS 20.Lubricate centre screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown to remove mounting from transfer gearbox. CAUTION: Ensure tool alignment indicator is at the 6 oclock position. The tool alignment indicator is a machined flat on LRT-41-018/1 and LRT-41-018/2. Refit 1.Clean mounting and mating faces. 2.Lubricate new mounting and bore in transfer gearbox casing to aid assembly. 3.Position new mounting to rear face of transfer gearbox, and start entry. Mounting to be parallel, with timing marks aligned. NOTE: Transfer timing mark to side of mounting to assist with alignment. 4.Lubricate centre screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown, to fit mounting to transfer gearbox. Start with the centre screw at full length and when the mounting is approximately 75 percent fitted, reduce the length of the centre screw by screwing it fully into the base plate LRT-41-018/1. This will ensure the centre screw LRT-41-018/4, does not foul on the gearbox fluid pan. CAUTION: Ensure tool alignment indicator is at the 6 oclock position. 5.Ensure the mounting is fitted parallel. If necessary, use a mallet and tap the base plate to maintain a parallel fit. 6.Fit multiplug brackets, tighten bolts to 25 Nm (18 lbf.ft) 7.Clean transfer gearbox and mating face dowels and dowel holes. 8.Clean input shaft and mating face. M12 7539A LRT-41-018/2LRT-41-018/1 LRT-41-018/4 M12 7540A LRT-41-018/4 LRT-41-018/3 LRT-41-018/1
TRANSFER BOX REPAIRS 41-9 9.Apply thin coat of anti-seize grease to shaft splines. 10.Fit transfer gearbox and tighten Torx bolts to 43 Nm (32 lbf.ft). 11.Connect multiplug. 12.Connect breather hose to gearbox. 13.Fit and secure oxygen sensor leads. 14.Remove support from transfer gearbox. 15.Fit snubbers. 16.Fit cross member to mounting, fit nut and bolt but do not tighten at this stage. 17.Raise gearbox on jack. 18.Align cross member, fit bolts and tighten to 68 Nm (50 lbf.ft). 19.Remove support from gearbox. 20.Tighten nut and bolt securing mounting to cross member to 100 Nm (74 lbf.ft). 21.Fit heat shield and secure with nuts. 22.Fit rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 23.Fit front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 24.Refill transfer gearbox with oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. 25.Fit fan to pulley and tighten viscous coupling nut to 45 Nm (33 lbf.ft). Oil seal - input shaft $% 41.20.50 Remove 1.Remove transfer gearbox. + TRANSFER BOX, REPAIRS, Transfer gearbox - Td6. + TRANSFER BOX, REPAIRS, Transfer gearbox - V8. 2.Lever input shaft oil seal from transfer gearbox. Refit 1.Clean oil seal recess in transfer gearbox. 2.Using LRT-41-019 fit seal to transfer gearbox. 3.Fit transfer gearbox. + TRANSFER BOX, REPAIRS, Transfer gearbox - Td6. + TRANSFER BOX, REPAIRS, Transfer gearbox - V8. M41 7846 LRT-41-019
TRANSFER BOX 41-10 REPAIRS Oil seal - front output shaft $% 41.20.51 Remove 1.Drain transfer gearbox oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. 2.Remove front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 3. Diesel models only: Remove mass damper. + TRANSFER BOX, REPAIRS, Damper - vibration - Td6. 4.Release output shaft flange nut stake. 5.Using LRT-51-003 to restrain drive flange, remove nut and remove drive flange. Discard nut and O ring. 6.Remove seal from transfer gearbox. Refit 1.Clean oil seal recess in transfer gearbox. 2.Using LRT-41-020 fit seal to transfer gearbox box.3.Clean drive flange and mating face. 4.Fit flange, use new O ring and tighten new nut to 100 Nm (74 lbf.ft). 5.Stake output shaft flange nut to shaft. 6.Fit front propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - front. 7. Diesel models only: Fit mass damper. + TRANSFER BOX, REPAIRS, Damper - vibration - Td6. 8.Refill transfer gearbox with oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. M41 7848 LRT-51-003 M41 7849 LRT-41-020
TRANSFER BOX REPAIRS 41-11 Oil seal - rear output shaft $% 41.20.54 Remove 1.Remove rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 2.Release output shaft flange nut stake. 3.Using LRT-51-003 to restrain drive flange, remove nut and remove drive flange. Discard nut and O ring. 4.Remove seal from transfer gearbox. Refit 1.Clean oil seal recess in transfer gearbox. 2.Using LRT-41-020 fit seal to transfer gearbox box. 3.Clean drive flange and mating face. 4.Fit flange, use new O ring and tighten new nut to 100 Nm (74 lbf.ft). 5.Stake output shaft flange nut to shaft.6.Fit rear propeller shaft. + DRIVESHAFTS, REPAIRS, Propeller shaft - rear. 7.Check and if necessary, top up transfer gearbox oil. + TRANSFER BOX, ADJUSTMENTS, Drain and refill. M41 7850 LRT-51-003 M41 7851 LRT-41-020