1996 LAND ROVER DEFENDER transmission

TRANSFER GEARBOX
1
REPAIR TRANSFER GEARBOX
Service repair no - 41.20.25
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
adaptor plateLRT-99-010.
WARNING: Where use of a transmission
hoist is necessary, it is absolutely
essential to follow the manufacturers'
instructions to ensure safe and effective use of
the equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
.
1.Position vehicle on a ramp.
2.Select LOW range gear and leave vehicle in
neutral.
3.Disconnect battery.
4.Remove front, centre, seat cushion, or cubby
box
See CHASSIS AND BODY, Repair,
Cubby box
.
5.If fitted, disconnect multi-plug from EGR control
unit located on base of seat cushion or cubby
box.
6.Remove 4 screws securing centre access panel
to seat or cubby box base.
7.Release EGR and alarm system diagnostic
connector mounting bracket.
8.Lift up access panel, complete with diagnostic
connector harness, and place aside.
9.Remove breather pipe union from transfer
gearbox high/low cross-shaft housing.
10.Remove retaining clip and disconnect high/low
lever from operating rod.

41TRANSFER GEARBOX
2
REPAIR
11.Remove 3 trim studs and lift up handbrake
gaiter.
12.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
13.Release handbrake outer cable from heelboard.
14.Remove fan cowl
See COOLING SYSTEM,
Repair, Fan cowl
.
15.Raise vehicle on ramp.
16.Drain transfer box oil
See SECTION 10,
Maintenance, Under vehicle maintenance
.
17.Remove intermediate silencer.
See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90
orSee MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 110/130
.
18.Mark rear propeller shaft drive flange and
transmission brake drum for reassembly.
19.Remove 4 nuts, disconnect propeller shaft from
brake drum, and tie aside.
20.Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
21.Remove 4 nuts, disconnect propeller shaft from
transfer box, and tie aside.
22.Remove retaining clip at lower end of pivot arm
and disconnect differential lock control operating
rod.

TRANSFER GEARBOX
5
REPAIR REV: 05/9963.Feed transmission brake cable through heel
board. Ensure cable grommet is correctly
located.
NOTE: Apply a soap solution to aid fitment
of cable.
64.Lower vehicle ramp.
65.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
66.Connect high/low lever to operating rod.
67.Fit breather pipe banjo union to high/low
cross-shaft housing.
68.Fit centre access panel to seat base. If fitted,
secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.
69.If fitted, reconnect multi-plug to EGR control unit
on base of centre seat cushion or cubby box.
70.Fit seat cushion or cubby box
See CHASSIS
AND BODY, Repair, Cubby box
.
71.Reconnect battery.
72.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Handbrake
cable
.

TRANSFER GEARBOX
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................

PROPELLER SHAFTS
1
DESCRIPTION AND OPERATION PROPELLER SHAFT
Description
The front and rear propeller shafts have non-constant
velocity type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and protected by a rubber gaiter. A
grease nipple is also fitted for servicing requirements.
The front shaft which is shorter than the rear is
'phased', with the joints at each end, A and B
mis-aligned as shown.
The phasing is necessary on the front shaft only to
allow for greater variation in angular changes.
Propeller shaft
1.Flanged yoke
2.Grease nipple
3.Journal spider
4.Needle roller bearing
5.Circlip
6.Splined shaft
7.Rubber gaiter (dust cap)
8.Splined shaft

BRAKES
15
REPAIR
TRANSMISSION BRAKE
1.Pin
2.Washer
3.'C' clip
4.Brake shoe
5.Cable lever
6.Hold down spring
7.Dished washer
8.Brake drum
9.Screw
10.Brake cable
11.Adjuster slide
12.Aadjuster nut13.Spring
14.Adjuster slide
15.Adjuster bolt
16.Dished washer
17.Hold down spring
18.Brake shoe
19.Hold down pin
20.Hold down pin
21.Abutment plate
22.Back plate
23.Spring

70BRAKES
16
REPAIRREV: 05/99 TRANSMISSION BRAKE SHOES
Service repair no - 70.45.18
Remove
1.Park vehicle on level ground, chock road wheels
and release handbrake. Alternatively, raise
vehicle on a ramp.
2.Disconnect rear propeller shaft from
transmission output flange at brake drum.
3.Slacken off transmission brake drum adjustment
bolt.
4.Remove single screw securing brake drum to
output flange.
5.Withdraw drum to expose brake assembly.
6.Release top and bottom springs from brake
shoes, see J6337.
7.Grip dished washer with a pair of pliers, depress
washer and turn through 90°.
8.Remove dished washer, complete with hold
down spring and pin from both shoes.
9.Move brake shoes out from adjuster slides,
release from abutment plate and remove from
backplate.
10.Check that springs are satisfactory for continued
use. If new brake shoes are to be fitted, the
srings should also be renewed.Refit
11.Locate RH brake shoe in slide and secure brake
shoe and lever assembly to backplate with hold
down pin, spring and dished washer.
12.Locate LH brake shoe in slide and fit abutment
plate between both brake shoes. Secure LH
shoe with hold down pin, spring and dished
washer.
13.Fit pull-off springs to brake shoes.
14.Fit brake drum. Tighten screw to
25 Nm (18
lbf/ft).
15.Check that hand brake lever is released.
16.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
17.Tighten adjuster bolt to
25 Nm (18 lbf/ft)to
ensure brake drum is locked.
18.Slacken off adjuster bolt by 1.5 turns to give
shoes a running clearance. Check that the drum
is free to rotate.
19.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm (34 lbf/ft).
20.Remove wheel chocks and check operation of
handbrake.

BRAKES
17
REPAIR HANDBRAKE CABLE
Service repair no - 70.35.25
Remove
1.Park vehicle on level ground, chock road wheels
and release handbrake. Alternatively, raise
vehicle on ramp.
2.Remove 3 trim studs and lift up handbrake
gaiter.
3.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever.
4.Slacken off transmission brake drum adjusting
screw.
5.Disconnect propeller shaft from output flange.
6.Remove retaining screw and withdraw brake
drum.
7.Release handbrake cable clevis from abutment
on cable lever, see J6337, and pull through
aperture in back plate.
8.Pull cable from heelboard and remove from
vehicle.
Refit
9.Feed new cable through heelboard ensuring
rubber grommet is correctly located.
10.Position cable over guide plate, insert through
backplate and connect to cable lever.
11.Fit cable to handbrake lever and secure with
clevis pin and split pin.
12.Fit handbrake gaiter.
13.Fit brake drum. Tighten screw to
25 Nm (18
lbf/ft).
14.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
15.Tighten adjuster bolt further to
25 Nm (18 lbf/ft)
to ensure brake drum is locked.
16.Slacken off adjuster bolt by 1.5 turns to give
brake shoes running clearance. Check that the
drum is free to rotate.
17.Slacken locknut and adjust cable to give the
handbrake pawl two notches free movement on
the rachet before being fully operational on third
notch (brake shoes are fully expanded against
drum).
NOTE: Cable adjustment is for a new cable
or to compensate for cable stretch. Cable
adjustment must not be used to take up
brake shoe wear.
18.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm (34 lbf/ft).
19.Remove wheel chocks and check operation of
handbrake.