1996 LAND ROVER DEFENDER gearbox

ENGINE
5
REPAIR
26.Disconnect both pipes from fuel lift pump.
27.Release fuel feed pipe from retaining clip on air
cleaner bracket.
28.Disconnect vacuum hose from brake servo.
29.Remove oil pipes from oil filter adaptor.30.Using suitable hoist, fit chains to lifting brackets
and support engine.
31.Remove nuts and plain washers securing front
engine mountings to chassis.
32.Support gearbox.
33.Remove engine to bell housing fixings, leaving
starter motor attached to engine.
34.Carefully raise engine to release from gearbox.
35.Ensure all relevant connections to engine have
been removed.
36.Remove engine.
Refit
37.Clean bell housing.
38.Apply Hylomar sealant to mating faces of bell
housing and flywheel housing.
39.Lubricate splines of gearbox primary pinion with
Rocol MV 3.
40.Carefully lower engine into position and locate
primary pinion into clutch and engage bell
housing dowels.
41.Fit engine to bell housing fixings. Tighten to
40
Nm (30 lbf/ft).

12ENGINE
6
REPAIR 42.Raise engine, and locate front engine mountings
to chassis.
43.Remove gearbox support and lower engine.
44.Tighten front engine mounting to chassis fixings
to
45 Nm (33 lbf/ft).
45.Release chains from engine lifting brackets and
remove hoist.
46.Connect oil cooler pipes to oil filter adaptor.
47.Fit vacuum hose to brake servo adaptor.
48.Secure fuel feed pipe in retaining clip on air
cleaner bracket.
49.Fit fuel lift pump pipes.
50.Connect feed and spill return pipes to injector
pump.
51.If fitted, reconnect hand throttle cable to
mounting bracket and injector pump.
52.Fit outer cable adjusting nut into injector pump
mounting bracket.
53.Fit inner throttle cable to injector pump and
secure with clevis and split pin.
54.Secure bleed hose in retaining clips on front
timing cover.
55.Fit bleed hose to thermostat housing.
56.Connect inlet and outlet hoses to power steering
pump.
57.Fit down pipe to exhaust manifold and secure
with 3 nuts.
58.Connect starter motor battery and fuse box
leads.
59.If fitted, connect EGR valve multi-plug and
vacuum pipe.
60.Secure breather pipe clip to cylinder head.
61.Connect engine harness multi-plug.
62.Fit heater plug feed wire.
63.Connect electrical feed plug at rear of cylinder
head.
64.Fit heater hoses to cylinder head and heater
rails.
65.Fit feed pipe/hose to turbo-charger and
intercooler.
66.Fit rocker cover insulation.
67.Fit radiator assembly.
See COOLING SYSTEM,
Repair, Radiator
If applicable, fit air
conditioning condenser, compressor pipes and
heater matrix hoses.
See AIR CONDITIONING,
Repair, Condenser
68.Fit bonnet.
69.Reconnect battery.CRANKSHAFT PULLEY
Service repair no - 12.21.01
Remove
1.Disconnect battery.
2.Drain coolant.
See COOLING SYSTEM,
Repair, Drain and refill cooling system
3.Remove top hose from radiator.
4.Remove intercooler to induction manifold hose.
5.Remove viscous coupling and fan.
See
COOLING SYSTEM, Repair, Viscous
coupling and fan
6.Remove fan cowl.See COOLING SYSTEM,
Repair, Fan cowl
7.Remove drive belt.See ELECTRICAL, Repair,
Auxiliary drive belt
8.Fit crankshaft pulley retainerLRT-12-080and
secure with 4 bolts.
9.Remove crankshaft pulley retaining bolt
anti-clockwise using socket and suitable long
bar.
10.Remove pulley retainer.
11.Remove pulley, if necessary using extractor
LRT-12-049with thrust pad fromLRT-12-031.

ENGINE
15
REPAIR FLYWHEEL
Service repair no - 12.53.07
Remove
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Fit 2, long, 8 mm bolts into the clutch bolt holes,
as shown, to use as handles when lifting the
flywheel off the crankshaft.
5.Remove fan cowl.
See COOLING SYSTEM,
Repair, Fan cowl
6.Fit crankshaft pulley retainerLRT-12-080and
secure with 4 bolts, to restrain crankshaft while
removing flywheel retaining bolts.
7.Remove bolts and lift off flywheel.
Refit
NOTE: To prevent excessive flywheel
run-out, ensure that mating faces of
flywheel and crankshaft are clean.
8.Locate flywheel on crankshaft, remove lifting
bolts, and secure flywheel with new patched
retaining bolts, progressively tighten to
147 Nm
(108 lbf/ft).
9.Check the flywheel for possible run-out by
mounting a dial test indicator with the stylus in a
loaded condition resting on the flywheel face at a
radius of 114 mm (4.50 in) from the centre.
10.Turn flywheel and check that run-out does not
exceed 0,07 mm (0.003 in).
11.Should run-out be excessive, remove flywheel
and check again for irregularities on crankshaft
and flywheel mating faces and location dowel.
12.Remove crankshaft pulley retainer.
13.Fit fan cowl.
See COOLING SYSTEM, Repair,
Fan cowl
14.Fit clutch.See CLUTCH, Repair, Clutch
assembly
15.Fit gearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
16.Reconnect battery.

12ENGINE
16
REPAIR CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
NOTE: The crankshaft rear oil seal is
retained in its own housing, if the seal
requires replacing, the complete housing
assembly (1) must be renewed. Housing and seal
assemblies are supplied with their own
former/seal guide (2) already fitted. This former
must not be removed before fitting the assembly
to the engine. If a seal and housing assembly is
received without a former/guide fitted it must be
returned to the supplier. Used formers/guides
must be discarded immediately after use, under
no circumstances should they be reused on other
assemblies.
NOTE: A different rear oil seal housing,
with integral 'O' ring seal and gasket, was
fitted on earlier engines. They must be
replaced with the current housing and gasket (3)
shown below.
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove 5 bolts and withdraw seal housing,
complete with gasket.
Refit
NOTE: The raised side of groove at the
bottom of seal housing gasket must be
fitted to cylinder block face.
6.Insert slave studs to locate seal housing gasket.
7.Position new gasket over slave studs and
crankshaft flange onto cylinder block.
8.Fit new seal housing assembly, with
former/guide in-situ, over crankshaft flange. This
action will eject former/guide.
9.Secure assembly to cylinder block, removing
slave studs individually and inserting bolts.
Tighten to
25 Nm (18 lbf/ft).
10.Refit flywheel.See Flywheel

ENGINE
17
REPAIR 11.Refit clutch.
See CLUTCH, Repair, Clutch
assembly
12.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 gearbox
13.Reconnect battery.
CRANKSHAFT BEARING BUSH
Service repair no - 12.21.45
Remove
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove bearing bush.
NOTE: The bearing bush can be removed
by using one of the following methods.
Method 1.
Obtain a short length of steel rod of a diameter having
a good slide fit in the bore of the bush. Pack the bore
with grease and insert the steel rod into the end of the
bore, give a sharp blow with a hammer and the
grease should drive out the bush. It is recommended
that the bush and rod be covered by a suitable cloth
or rag to prevent grease from splashing.Method 2.
Thread the bore of the existing bush and using a
suitable bolt extract the bush. Thoroughly clean bush
location ensuring all swarf is removed.
Refit
1.Fit new bush using a suitable shouldered drift,
inserting bush flush with end of crankshaft.
2.Refit flywheel.
See Flywheel
3.Refit clutch.See CLUTCH, Repair, Clutch
assembly
4.Refit gearbox.See MANUAL GEARBOX,
Repair, R380 gearbox
5.Reconnect battery.

12ENGINE
18
REPAIR FLYWHEEL HOUSING
Service repair no - 12.53.01
Remove
1.Disconnect battery.
2.Remove gearbox.
See MANUAL GEARBOX,
Repair, R380 gearbox
3.Remove clutch.See CLUTCH, Repair, Clutch
assembly
4.Remove flywheel.See Flywheel
5.Remove 3 fixings and withdraw starter motor.
6.Remove 2 bolts from top of flywheel housing.
7.Remove 4 bolts securing bottom of flywheel
housing to engine mounting brackets.
8.Remove inner bolts and lift off flywheel housing.Refit
9.Clean rear face of housing and mating face on
block, ensuring all old sealant is removed.
10.Apply sealant to flywheel housing mating face on
cylinder block.
11.Fit housing to cylinder block. Tighten retaining
bolts to
45 Nm (33 lbf/ft).
12.Remove surplus sealant from block.
13.Fit starter motor.
14.Fit flywheel.
See Flywheel
15.Fit clutch.See CLUTCH, Repair, Clutch
assembly
16.Fit gearbox.See MANUAL GEARBOX, Repair,
R380 gearbox
17.Reconnect battery.

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit comprises a single dry plate friction
disc and diaphragm spring clutch unit, secured to the
engine flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder (12) and a slave cylinder (13) attached to the
transmission bell housing.
Clutch components
1.Crankshaft and flywheel
2.Friction plate
3.Clutch cover
4.Diaphragm spring
5.Pressure plate
6.Fulcrum posts (9) for diaphragm spring
7.Bearing rings (2) for diaphragm spring
8.Retraction links and bolts (3) for pressure plate
9.Release bearing10.Release lever
11.Release lever pivot post
12.Master cylinder
13.Slave cylinder
14.Master cylinder pedal pushrod
15.Primary shaft and taper bearing (in gearbox)
16.Gearbox front cover
17.Primary shaft flywheel bush
18.Pedal pivot and return spring

33CLUTCH
2
DESCRIPTION AND OPERATION
When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever (10), bearing (9), to the inner fingers of the
diaphragm spring (4).
The diaphragm spring (4) pivots on the bearing rings
(7) and fulcrum posts (6) causing the pressure plate
(5) to release the clamping force on the friction plate
and linings (2).As the the clamping force is removed from the friction
plate (2), the plate slides on the splines of the primary
shaft (15) and takes up a neutral position between the
flywheel (1) and the pressure plate (5), thus
disconnecting the drive between the engine and the
gearbox.