Land Rover Range Rover Classic Workshop 1995 Rover Manual

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OVERHAUL 23.Fit the snap ring with the stepped ends adjacent
to the selector shaft bore.
24.Turn the rear cover over and fit the circlip to
retain the sun gear shaft.
25.Remove any previous sealant from the end cap.
Apply Dow Corning 732 silicon sealant or a
suitable equivalent to the outside diameter of the
rear cover, evenly tap the cap into position.
26.If necessary re - position the filter on the oil pick
- up pipe until the lug on the filter can be pushed
into the slot in the rear cover.
Selector fork
- Dismantle and inspection
1.Remove the retaining clip and separate the fork
from the arm.
2.Detach the two nylon slippers from the selector
fork feet and discard.
3.Thoroughly clean all components.
4.Examine the fork, arm and pivot pin for wear.
Renew as necessary.
5.Remove the O ring and discard. Examine the
shaft and lever for wear and damage, renew as
necessary.
6.Examine the selector sleeve teeth and internal
splines for damage and wear. Renew as
necessary. 
						

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OVERHAUL Selector fork - Assemble
7.Fit new nylon slippers to the fork.
8.Assemble the fork to the selector arm and
secure in position using a new retaining clip.
9.Lightly lubricate and fit the spring and selector
plunger.
10.While compressing the plunger and spring, fit the
selector fork, operating arm assembly and
selector sleeve simultaneously.
11.Select neutral gear position at the operating arm.
12.Fit a new O ring to the selector lever shaft.
Lubricate the O ring and fit the lever assembly
to the rear cover, noting that when fully
assembled the lever should lie parallel with the
joint face of the rear cover.
13.Fit a new retaining clip to secure the selector
fork operating arm to the selector lever shaft.
14.Remove any previous sealant from the Torx
screw. Align the selector lever shaft groove to
the retaining screw hole, apply a small amount of
Loctite 242 to the screw threads and using Torx
bit 25 fit and tighten the screw to the specified
torque. Ensure that the screw locates in the
groove of the shaft.
15.Clean any previous sealant from the Torx screw.
Apply a small amount of Loctite 242 to the
threads of the screw and fit to the selector fork
operating arm, tighten using Torx bit 25 to the
specified torque.
Bearing carrier
- Dismantle, inspection and assemble
1.Remove the circlip and drive or press the
transfer shaft from the bearing.
2.Remove the circlip retaining the bearing in the
carrier.
3.Drive or press the bearing from the carrier and
discard the bearing.
4.Clean and examine the carrier for cracks and
general condition. Renew as necessary.
5.Press or drive a new bearing into the carrier and
secure with the circlip. 
						

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OVERHAUL Transfer shaft
- Inspection and assemble
1.Clean the transfer shaft.
2.Visually examine the external splines for
damage and wear, if worn fit a new component.
3.Check the phospher bronze bush for wear by
measuring the internal diameter of the bush with
internal calipers and a micrometer or with an
internal micrometer. The bush diameter must not
exceed 38.515 mm (1.516 in) fit a new transfer
shaft if the bush has worn above the figure
given.
4.Drive or press the transfer shaft into the bearing
in the carrier. Secure the shaft with the circlip.
5.Fit the carrier to the rear cover, fit the anti -
rotation dowel and secure the assembly with the
snap ring, noting that the open ends of the snap
ring must be positioned by the cast relief in the
bearing carrier upper face.
Transfer sprocket - Inspection
1.Examine the sprocket teeth and splines for wear
and damage, if either are evident discard the
sprocket, otherwise clean and place to one side.
Chain - Inspection
NOTE: A stretched chain can be identified
by either excessive noise when the
gearbox is operational or by witness
marks on the inside edges of the case. If either is
evident, renew the chain.
1.Using a suitable solvent thoroughly clean the
chain.
2.Check the chain links for wear and damage, if
necessary renew the chain.
3.Place the chain to one side. 
						

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OVERHAUL Centre differential and sprocket
- Dismantle and inspection
1.Place the differential unit in a vice fitted with soft
jaws. If the original components are to be refitted
mark an identification line on the sprocket and
differential unit.
2.Remove the bolts securing the sprocket to the
differential.
3.Lift the differential assembly from the sprocket.
4.Examine the sprocket teeth for wear and
damage, if either are evident renew the sprocket.
Place the sprocket aside until the differential is
ready to be assembled.
Centre differential
- Dismantle and inspection
1.Using a two legged puller, ease the bearings
from the differential assembly and discard the
bearings.
2.Secure the front half of the differential unit in a
vice fitted with soft jaws, remove the eight
retaining bolts securing the front and rear halves
of the assembly together, lift off the rear part of
the differential unit. Note the identification marks
on the exterior of the differential unit. 
						

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OVERHAUL 3.Remove the rear upper bevel gear and thrust
washer.
4.Remove the pinion gears and dished washers
along with the cross shaft.
5.Remove the front lower bevel gear and thrust
washer from the front half of the differential unit.
6.Remove the front half of the differential unit from
the vice and clean all components. Examine for
wear or damage, renew if necessary.
Differential pinions - rolling resistance
7.Using soft jaws secure the front half of the
differential unit in the vice.
8.Fit the front bevel gear without the thrust washer.
Lightly lubricate and fit the cross shaft, pinion
gears and new dished washers.
9.Fit the rear bevel gear together with the thinnest
thrust washer to the rear half of the differential.
Assemble both halves of the differential noting
the identification marks. Fit the bolts and tighten
to the specified torque.
10.Invert the differential unit in the vice, fit the front
output housing to the differential, locating the
viscous unit splines on the front bevel gear. Fit
the drive flange to the viscous unit and place the
brake drum on top of the drive flange, secure
with the nut. Check that the gears are free to
rotate.
11.Tie a length of string around the brake drum,
attach a spring balance to the free end and
carefully tension the string until a load to turn is
achieved. Alternatively use a torque wrench
applied to the drive flange nut. Rotate the brake
drum slowly by hand to overcome the initial load
when using either method.
NOTE: Gears that have been run will rotate
smoothly and will require a torque of 0.56
Nm (5 in lb), equivalent force using a
spring balance 0.45 kg (1 lb). New gears will rotate
with a notchy feel and will require a torque of not
more than 2.26 Nm (20 in lb), equivalent force
using a spring balance 7.72 Kg (3.8 lb). Keep all
components lubricated when carrying out these
adjustments.
12.Change the thrust washer for a thicker one if the
torque reading is too low and re - check the
torque. Five thrust washers are available in
0.10mm steps ranging from 1.05 to 1.45mm.
13.Dismantle the unit when the rear bevel gear
thrust washer has been selected.
14.Remove and retain the rear bevel gear and
thrust washer combination. 
						

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OVERHAUL 15.Repeat the procedure to obtain the correct thrust
washer for the front bevel gear, it is not
necessary to fit the rear bevel gear when
checking the front bevel gear rolling resistance.
16.When the thrust washer has been selected for
the front bevel gear, again dismantle the
differential unit and retain the thrust washer and
front bevel gear combination.
Centre differential - Assemble
17.Fit the thrust washer and front bevel gear into
the front half of the differential unit.
18.Fit the pinion gears with dished washers to the
cross shaft and fit the assembly to the differential
unit.
19.Fit the thrust washer and rear bevel gear to the
rear half of the differential unit.
20.Align both halves of the differential noting the
identification marks. Secure both halves together
with the eight bolts. Tighten the bolts to the
specified torque.
21.Check the overall torque required to turn the
differential, this should be approximately equal to
both bevel gears added together.
22.Drive or press new bearings onto the differential,
noting that the smaller of the two bearings is
fitted to the rear half of the differential.
Centre differential sprocket - Assemble
1.Fit the sprocket to the differential noting that the
face of the sprocket with the relieved threads
must contact the flange of the differential
housing. Observe the previously marked
identification lines if the original components are
being refitted.
2.Fit new bolts and tighten evenly to the specified
torque.
Transfer sprocket, centre differential assembly
and chain - Assemble
1.Place the differential assembly and transfer
sprocket inside the chain. If the original
components are being refitted observe the
identification marks previously applied to the
chain and transfer sprocket. Fit the complete
assembly simultaneously.
2.Carefully tap the differential bearing into its bore
while easing the transfer sprocket onto the
transfer shaft. 
						

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OVERHAUL
3.Ensuring that the transfer sprocket is fully down,
secure the sprocket to the transfer shaft with the
circlip.
Front and rear cover - main casing - Assemble
1.Ensuring that the joint faces of the front and rear
covers are clean, apply a bead of Dow Corning
732 or a suitable equivalent silicone sealant to
the joint face of the rear cover and evenly spread
the sealant over the face. Do not over apply the
sealant.
2.Fit the front cover, secure with the eleven bolts,
tightening evenly to the specified torque. Do not
wipe away the surplus sealant which is forced
out of the joint.
Rear output housing
- Dismantle and inspection
Service tools:
18G1422 - Oil seal replacer
18G1205 - Adjustable flange holding wrench
1.Support the rear output housing by the output
shaft in a vice fitted with soft jaws.
2.Using service tool 18G1205 to restrain the drive
flange, release and remove the nyloc nut and
plain washer securing the drive flange to the
output shaft, withdraw the rubber seal. Discard
the nut and seal.
3.Remove the drive flange from the output shaft.
Examine the flange for damage or wear
particularly the seal running surface, if the
surface is corroded or a groove has been worn
by the previous seal discard the flange.
4.Prise the speedometer sleeve and driven gear
from the housing. Examine the gear teeth for
wear, if worn discard the gear.
5.Prise the oil seal from the sleeve and remove the
O ring, discard both the seal and O ring. 
						

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OVERHAUL 6.Clean the sleeve and place to one side.
7.Drive or press the output shaft from the housing.
8.Clean and examine the splines and
speedometer drive gear for wear or damage.
The output shaft can be further dismantled if
either the speedometer drive gear or output shaft
is worn: remove the circlip and slide the gear
from the shaft, retrieve the ball bearing from the
indent in the shaft. Discard the worn component.
NOTE: While the output shaft is removed
from the rear output housing, the shaft can
be utilised for checking the rolling
resistance of the viscous unit as follows.Viscous unit - rolling resistance
Bench check
NOTE: Testing should be carried out in an
ambient of 20 ÊC.
9.Secure the output shaft in a vice fitted with soft
jaws, gripping the shaft on the drive flange
splines.
10.With the viscous unit still installed in the front
output housing place the assembly on the rear
output shaft spline.
11.Apply a clockwise torque of
27 Nmto output
flange nut. If no resistance to turn is felt, unit
requires replacing.
12.If resistance to turn is felt, apply a clockwise
torque of
20Nm,to output flange nut for 1
minute, this should result in a rotation of
approximately 25Ê - 30Ê. If no rotation or a
greater force is required, unit requires replacing. 
						

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OVERHAUL Rear output housing (continued)
13.Lever off the dust shield.
14.Prise the oil seal from the housing and discard
the seal.
15.Remove the circlip retaining the bearing.
16.Drive or press the bearing from the housing.
Discard the bearing.
17.Remove any previous sealant from the housing
joint face.
18.Thoroughly clean all components with a suitable
solvent.
19.Examine the housing for damage and wear.
Renew as necessary.
Rear output housing - Assemble
20.Drive or press a new bearing into the housing
until the bearing contacts the shoulder.
21.Fit the circlip.
22.Lubricate a new oil seal. Using oil seal replacer
18G1422 fit the seal, lip side leading until it
contacts the circlip.
23.Fit the dust shield.
24.Place the ball bearing in the indent on the output
shaft, fit the speedometer drive gear to the shaft,
secure together with the circlip.
25.Press or drive the output shaft into the housing
until the shoulder of the shaft contacts the
bearing.
26.Lubricate the oil seal bearing surface of the drive
flange and fit the flange followed by a new
rubber seal. Fit the steel washer and secure the
flange to the shaft using a new nut. Tighten to
the specified torque.
27.Lubricate a new speedometer sleeve oil seal,
press the seal into the top of the sleeve.28.Fit a new O ring to the outside of the sleeve,
push the driven gear spindle into the sleeve.
29.Lubricate the O ring and push the sleeve and
gear assembly into the housing. It may be
necessary to rotate the output shaft to ensure
that the driven gear engages with the drive gear
on the shaft.
30.Apply Dow Corning 732 or a suitable equivalent
silicone sealant to the rear output housing joint
face on the main casing. Evenly spread the
sealant on the face to ensure a good seal.
31.Fit the housing to the main casing and secure
with the six bolts tightened to the specified
torque.
Front output housing
- Dismantle and Inspection
Service tools:
18G1422 - Oil seal replacer.
18G1205 - Adjustable flange holding wrench
1.Support the viscous unit and front output
housing in a vice fitted with soft jaws gripping on
the two flats of the viscous unit.
2.Using service tool 18G1205 to restrain the drive
flange, release and remove the nyloc nut and
plain washer securing the drive flange to the
output shaft, withdraw the rubber seal. Discard
the nut and seal.
3.Remove the drive flange from the viscous unit.
Examine the flange for damage or wear
particularly the seal running surface, if the
surface is corroded or a groove has been worn
by the previous seal discard the flange. 
						

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OVERHAUL 4.If necessary the oil catcher can be carefully
pressed from the drive flange, if either a new oil
catcher or bolts are being fitted.
5.Carefully tap the viscous unit out of the housing.
If the original unit is being refitted wipe clean
with a clean cloth.
NOTE: The viscous unit is a sealed
assembly and cannot be further
dismantled, a new unit should be fitted if
the unit is damaged or if the torque to turn is out
of limits.
6.Prise the oil seal out from the front output
housing and discard.
7.Remove the circlip retaining the bearing.
8.Drive or press the bearing from the housing and
discard.9.Clean the housing with a suitable solvent.
10.Remove any previous sealant from the joint face
of the housing.
11.Examine the housing for damage and wear,
renew the housing if necessary.
Front output housing - Assemble
12.Drive or press a new bearing into the housing
13.Fit the circlip to retain the bearing.
14.Lubricate a new oil seal. Using oil seal replacing
tool 18G1422 fit the seal, lip side of the seal
leading until it contacts the circlip.
15.Carefully tap the original or new viscous unit into
the housing until contact is made with the face of
the bearing.
16.Lubricate the lips of the seal and fit the flange
followed by a new rubber seal; fit the steel
washer and secure the flange with a new nut.
Tighten to the specified torque.
17.Apply Dow Corning 732 or a suitable equivalent
silicone sealant to the output housing joint face
of the main casing. Evenly spread the sealant on
the face to ensure a good seal.
18.Fit the housing to the main casing and secure in
position with the eight bolts tightened evenly to
the specified torque.
19.Refit the gearbox to the vehicle.