1999 LAND ROVER DEFENDER shaft

37MANUAL GEARBOX
2
REPAIR
7.Using a soft metal drift, carefully remove input
shaft front bearing track from front cover.
CAUTION: Take care not to damage
bearing track, if track is damaged, it will be
necessary to fit a new input shaft front
bearing.
8.Remove input shaft oil seal from front cover;
discard oil seal.
Refit
9.Using a suitable solvent clean seal recess, front
cover and gearbox mating faces; clean threads
of bolts and bolt holes.
10.Clean bearings and bearing races.
11.Lubricate a new oil seal with gearbox oil.
12.Fit oil seal using a suitable mandrel.
13.Fit input shaft front bearing track using a press
and suitable mandrel.
14.Apply sealant, Part No. STC 4404 to front cover.
15.Position front cover, apply Loctite 290 to threads
of bolts; fit new bolts and tighten by diagonal
selection to25 Nm (18 lbf.ft).
16.Clean clutch housing mating faces, dowels and
dowel holes.
17.Position clutch housing, fit bolts and tighten by
diagonal selection to75 Nm (55 lbf.ft).
18.Clean bearing sleeve mating faces, dowel and
dowel holes.
19.Position bearing sleeve, fit bolts and tighten to
25 Nm (18 lbf.ft).
20.Examine clutch release fork pivot points for wear
and replace as required.
21.Apply a smear of Molybdenum disulphide grease
to pivot points and position release fork.
22.Fit retaining clip ensuring it locates over pivot
point washer, fit bolt and tighten to10 Nm (7
lbf.ft).23.Clean release bearing and bearing sleeve
mating faces.
24.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
25.Fit release bearing and secure with retaining
peg.
26.Fit gearbox.See this Section.
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37MANUAL GEARBOX
8
REPAIR
12.Remove 13 screws securing tunnel cover.
13.Release and remove tunnel cover.
14.Remove cooling fan.See COOLING SYSTEM,
Repair.
15.Remove air filter.See FUEL SYSTEM, Repair.
16.Remove 2 upper bolts securing clutch housing to
engine.
17.Remove bolt securing shim to clutch housing.
18.Release gearbox breather pipes from clips on
heater hose.
19.Remove starter motor.See ELECTRICAL,
Repair.
20.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
21.Drain gearbox oil.See Adjustment.
22.Drain transfer gearbox oil.See
MAINTENANCE ,
23.Remove 3 nuts securing intermediate silencer to
tail pipe.
24.Release silencer from mounting rubbers, remove
silencer and discard gasket.
25.Mark front and rear propeller shaft to transfer
gearbox flanges for reassembly purposes.
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MANUAL GEARBOX
9
REPAIR
26.Remove 4 nuts securing front propeller shaft to
transfer gearbox, release propeller shaft from
output drive flange.
27.Remove 4 nuts, release rear propeller shaft from
brake drum.
28.Remove 2 bolts securing clutch slave cylinder,
release slave cylinder and position aside.
29.Fit support plateLRT-99-007to gearbox jack.
30.Position gearbox jack and support plate to
gearbox and secure with 3 bolts.
31.Support the weight of gearbox.
32.Remove 4 nuts securing LH and RH mountings
to chassis and transfer gearbox mounting
brackets.
33.Remove bolts securing mountings to gearbox,
raise gearbox and remove both mountings and
heat shield from LH mounting and brackets.
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MANUAL GEARBOX
11
REPAIR Refit
44.Clean gearbox to engine mating faces, dowels
and dowel holes.
45.With assistance raise gearbox on jack and align
to clutch and engine.
46.Fit lower bolts securing clutch housing to engine
and tighten to50 Nm (37 lbf.ft).
NOTE: Do not fit upper bolts at this stage.
47.Fit earth leads and secure with bolt.
48.Connect Lucars to differential lock switch,
multiplug to reverse light switch, position
multiplug to bracket and connect low ratio detect
multiplug - if fitted.
49.Raise gearbox jack and guide transfer gearbox
lever through tunnel.
50.Secure body harness clips to bracket on top of
transfer gearbox.
51.Position battery earth lead to transfer gearbox
and tighten retaining nut.
52.Connect multiplug to speed sensor and secure
harness in clip on transfer gearbox.
53.Position mounting brackets and rubber
mountings, positioning heat shield to LH
mounting and tighten bracket bolts to85 Nm (63
lbf.ft).
54.Position nuts to mountings and tighten to48 Nm
(35 lbf.ft).
55.Remove 3 bolts securing support plate
LRT-99-007to gearbox.
56.Position handbrake cable through heel board.
57.Position clutch slave cylinder, fit bolts and
tighten to25 Nm (18 lbf.ft).
58.Clean propeller shafts and mating faces.
59.Position propeller shafts, align to marks and
tighten nuts to48 Nm (35 lbf.ft).
60.Clean intermediate silencer and tail pipe mating
faces.
61.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts and
tighten to25 Nm (18 lbf.ft).
62.Refill gearbox with oil.See Adjustment.
63.Refill transfer gearbox with oil.See
MAINTENANCE ,
64.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
65.Refit starter motor.See ELECTRICAL, Repair.
66.Fit bolt securing shim plate to clutch housing and
tighten10 Nm (7 lbf.ft).
67.Position heater pipe to gearbox housing, fit
upper bolts securing clutch housing to engine
and tighten to50 Nm (37 lbf.ft).
68.Position gearbox breather pipes to clips on
heater hose.69.Fit air cleaner.See FUEL SYSTEM, Repair.
70.Fit cooling fan.See COOLING SYSTEM,
Repair.
71.Fit and align tunnel cover, fit and tighten screws.
72.Position relay panel, fit spacers and tighten
screws.
73.Position hand-brake lever and tighten bolts to25
Nm (18 lbf.ft).
74.Connect handbrake cable to lever, fit clevis pin,
washer and new split pin.
75.Connect Lucar to hand-brake switch.
76.Position gaiter to handbrake lever and secure
with trim stud.
77.Locate insulation pad over gear levers and fit to
tunnel cover.
78.Align spline marks, fit gear lever to lower lever,
fit washer and secure with retaining nut.
79.Position gear lever cover.
80.Position gearbox tunnel carpet.
81.Fit gear lever and transfer gear lever knobs.
82.Reconnect battery negative lead.
83.Fit battery cover.
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41 - TRANSFER GEARBOX
CONTENTS
Page
ADJUSTMENT
DIFFERENTIAL LOCK WARNING LAMP SWITCH 1.............................................
HIGH/LOW SELECTOR LINKAGE 1......................................................................
REPAIR
BOTTOM COVER - TRANSFER GEARBOX - RESEAL 1......................................
TRANSFER GEARBOX 1.......................................................................................
GASKET - REAR COVER PLATE 6.......................................................................
SWITCH - DIFFERENTIAL LOCK WARNING LAMP 7...........................................
SEAL - INPUT SHAFT 8.........................................................................................
SEAL - FRONT OUTPUT SHAFT 9........................................................................
SEAL - REAR OUTPUT SHAFT 10........................................................................
GASKET - REAR OUTPUT SHAFT HOUSING 12.................................................
SWITCH - LOW DETECT 13..................................................................................
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41TRANSFER GEARBOX
2
REPAIR
13.Release handbrake outer cable from heelboard.
14.Remove breather pipe banjo bolt from transfer
gearbox high/low cross shaft housing and
discard sealing washers.
15.Remove retaining clip and disconnect high/low
operating rod from lever.
16.Remove cooling fan.See COOLING SYSTEM,
Repair.
17.Remove front exhaust pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
18.Drain transfer gearbox oil.
19.Remove 3 nuts securing intermediate silencer to
tail pipe.
20.Release intermediate silencer from rubber
mountings and remove silencer from tail pipe,
discard gasket.
21.Using a centre punch, mark relationship between
front propeller shaft and transfer gearbox drive
flanges and rear propeller shaft and brake drum
drive flanges.
22.Remove 4 nuts securing front propeller shaft to
transfer gearbox drive flange and remove
propeller shaft.
23.Remove 4 nuts securing rear propeller shaft to
brake drum flange.
24.Release propeller shaft and tie aside.
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TRANSFER GEARBOX
5
REPAIR
43.If transfer gearbox is to be refitted, remove and
discard input shaft oil seal.
Refit
44.Clean mating faces of main gearbox extension
case and transfer gearbox.
45.Remove all traces of sealant from threads of
transfer gearbox securing bolts and studs.
46.Clean input shaft oil seal recess in transfer
gearbox.
47.Lubricate new input shaft oil seal with transfer
gearbox oil.
48.Using toolLRT-37-014, fit input shaft oil seal, lip
side facing inwards.49.Ensure guide studsLRT-41-009are fitted in
main gearbox extension case.
CAUTION: If securing studs were removed
during transfer gearbox removal, apply
Loctite 290 to threads of new studs; fit
studs and tighten to 45 Nm (33 lbf.ft).
50.Secure transfer gearbox to support plate
LRT-99-010, fit and tighten 4 bolts.
51.Raise transmission hoist until transfer gearbox
can be located over guide studsLRT-41-009.
52.Apply Loctite 290 to threads of securing bolts
and studs.
53.Fit and lightly tighten 2 nuts to secure transfer
gearbox to main gearbox extension case.
54.Remove guide studsLRT-41-009.
55.Ensuring bolts are in their original fitted
locations, fit and lightly tighten 4 bolts to secure
transfer gearbox to main gearbox extension
case.
56.Progressively tighten nuts and bolts to45 Nm
(33 lbf.ft).
57.Position earth leads to RH side of transfer
gearbox, fit and tighten bolt.
58.Connect low ratio detect switch multiplug and
secure to bracket. Connect Lucars to differential
lock warning lamp switch.
59.Raise gearbox jack and guide transfer gearbox
lever through tunnel.
60.Connect body harness clips to bracket on top of
transfer gearbox.
61.Position earth lead to transfer gearbox, tighten
nut to45 Nm (33 lbf.ft).
62.Connect speed sensor multiplug and secure
harness in clip.
63.Position heat shield to LH mounting, fit
mountings and brackets and tighten bolts to85
Nm (63 lbf.ft).
64.Fit nuts securing RH and LH mountings and
tighten to48 Nm (35 lbf.ft).
65.Position breather pipe to transfer gear box, fit
new sealing washers and tighten banjo bolts to
15 Nm (11 lbf.ft).
66.Remove bolts securing support plate to gearbox
jack.
67.Remove bolts securingLRT-99-010to transfer
gearbox.
68.Apply Loctite 290 to threads of bottom cover
securing bolts, fit bolts and tighten to25 Nm (18
lbf.ft)
69.Position differential lock control rod and secure
with retaining clip.
70.Clean rear propeller shaft to brake drum flange
mating faces.
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41TRANSFER GEARBOX
6
REPAIR 71.Release propeller shaft, align flange markings
and connect to studs.
72.Fit nuts securing propeller shaft and tighten to48
Nm (33 lbf.ft).
73.Clean front propeller to transfer gearbox flange
mating faces.
74.Fit propeller shaft, align flange markings and
tighten nuts to48 Nm (33 lbf.ft).
75.Using new gasket, fit intermediate silencer and
tighten nuts to25 Nm (18 lbf.ft).
76.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
77.Refill transfer gearbox with recommended oil.
78.Fit cooling fan cowl.
79.Fit high/low operating rod and secure with
retaining clip.
80.Position handbrake outer cable to heelboard.
81.Position handbrake cable to lever, fit clevis pin,
washer and new split pin.
82.Position handbrake gaiter and secure with trim
studs.
83.Fit insulation pad to tunnel.
84.Fit gear lever cover.
85.Fit gear lever knobs.
86.Position diagnostic plug bracket, access panel
and tighten screws.
87.Fit carpet to transmission tunnel.
88.Fit cubby box.See CHASSIS AND BODY,
Repair.
89.Fit cooling fan.See COOLING SYSTEM,
Repair.
90.Reconnect battery negative lead.
91.Fit battery cover.GASKET - REAR COVER PLATE
Service repair no - 41.20.30
Remove
1.Raise vehicle on’4 post ramp’.
2.Mark rear cover plate to bearing housing for
assembly purposes.
3.Noting fitted position of stud bolt and harness
clip bracket, remove 5 bolts and stud bolt
securing cover plate.
4.Collect harness clip bracket.
5.Remove cover plate.
Refit
6.Clean cover plate and mating face.
7.Apply Hylosil RTV 102 to rear cover mating face.
8.Align reference marks, fit cover plate.
9.Clean cover bolts and apply Loctite 290 threads
of bolts and stud nut.
10.Position clip bracket, fit stud nut and bolts,
tighten by diagonal selection to25 Nm (18
lbf.ft).
11.Check/top-up transfer gearbox oil.
12.Lower vehicle.
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