1999 LAND ROVER DEFENDER differential

TRANSFER GEARBOX
1
ADJUSTMENT DIFFERENTIAL LOCK WARNING LAMP SWITCH
Service repair no - 41.20.36
Adjust
NOTE: This procedure is only necessary
for switches fitted with a locknut in place
of the threaded spacer.
1.Move differential lock selector fork to differential
locked position.
2.Connect a 12V test lamp and battery to
differential lock warning lamp switch.
3.Screw switch in until test lamp is illuminated then
screw switch in a further 1/2 turn; tighten locknut.
4.Disengage differential lock, check that test lamp
is extinguished.
5.Remove test lamp.HIGH/LOW SELECTOR LINKAGE
Service repair no - 41.20.46
Adjust
1.Disconnect battery negative lead.
2.Remove gear lever knobs.
3.Remove gearbox tunnel carpet.
4.Remove gear lever (s) gaiter.
5.Release and remove insulation pad from around
gear levers.
6.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
7.Release bulkhead carpet from LH side of tunnel
and move aside.
8.Remove 2 bolts securing hand-brake lever to
body and move aside.
9.Remove 13 screws securing tunnel cover.
10.Release and remove tunnel cover.
11.Loosen linkage locknut.
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TRANSFER GEARBOX
3
REPAIR
25.Remove retaining clip at lower end of pivot arm
and disconnect differential lock control operating
rod.
26.Remove 4 central bolts from transfer gearbox
bottom cover, position support plateLRT-99-010
to transfer gearbox and tighten bolts.
27.Position gearbox support jack and secure
support plate to jack using 4 bolts.
28.Support the weight of the transfer gearbox.
29.Remove 4 nuts securing LH and RH mountings
to chassis and transfer gearbox mounting
brackets.
30.Remove 8 bolts securing mounting brackets to
transfer gearbox, raise gearbox and remove both
mountings, heat shield from LH mounting and
brackets.
31.Disconnect multiplug from speed sensor and
release harness from clip on transfer gearbox.
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41TRANSFER GEARBOX
4
REPAIR
32.Remove retaining nut and release battery earth
lead from transfer gearbox.
33.Release body harness clips from bracket on top
of transfer gearbox.
34.Lower gearbox jack sufficiently to allow transfer
gearbox lever to clear tunnel.
35.Disconnect Lucars from differential lock warning
lamp switch and multiplug from low ratio detect
switch, and release multiplug from bracket.
36.Remove bolt and release earth leads from RH
side of transfer gearbox.
37.Move the high/low selector lever upwards to gain
access to adjacent nut securing transfer gearbox
to main gearbox.
38.Position a jack to support main gearbox and
engine.
39.Noting their fitted positions, remove 4 bolts
securing transfer gearbox to main gearbox
extension case.
40.Fit 3 guide studsLRT-41-009through transfer
gearbox bolt holes to support it during during
removal.
41.Remove 2 nuts securing transfer gearbox to
main gearbox extension case.
CAUTION: If studs are removed during this
operation, they must be discarded and
new studs fitted.
42.With assistance, remove transfer gearbox from
main gearbox.
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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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TRANSFER GEARBOX
7
REPAIR SWITCH - DIFFERENTIAL LOCK WARNING LAMP
Service repair no - 41.20.34
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove gear lever knobs.
4.Remove gearbox tunnel carpet.
5.Remove gear lever (s) gaiter.
6.Release and remove insulation pad from around
gear levers.
7.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
8.Release bulkhead carpet from LH side of tunnel
and move aside.
9.Remove 2 bolts securing hand-brake lever to
body and move aside.
10.Remove 13 screws securing tunnel cover.
11.Release and remove tunnel cover.
12.Disconnect Lucars from differential lock warning
lamp switch.
13.Loosen and remove switch.
NOTE: Locknut fitted in place of spacer on
early transfer boxes.
14.Remove locknut/spacer from switch.
Refit
15.Clean switch, locknut/spacer and mating face on
gearbox.
16.Fit locknutnut/spacer to switch with counterbore
on spacer positioned towards switch head.
NOTE: To ensure that the switch setting is
correct, make sure the spacer is fully
tightened to switch head, (no gap).
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41TRANSFER GEARBOX
8
REPAIR 17.Apply Hylomar PL32 sealant to switch threads.
18.Position switch into gearbox housing until
locknut/spacer bottoms out on housing.
19. Switches fitted with spacer:Tighten spacer
securing differential lock switch to11 Nm (8
lbf.ft).
20.Connect Lucars to switch.
21. Switches fitted with locknut:Adjust switch.
See Adjustment.
22.Fit and align tunnel cover, fit and tighten screws.
23.Fit hand-brake lever and tighten bolts to25 Nm
(18 lbf.ft).
24.Secure bulkhead carpet to LH side of tunnel.
25.Position relay/fuse panel, fit spacers and tighten
screws.
26.Fit insulation pad around gear levers.
27.Fit gear lever (s) gaiter.
28.Fit gearbox tunnel carpet.
29.Fit gear lever knobs.
30.Reconnect battery negative lead.
31.Fit battery cover.SEAL - INPUT SHAFT
Service repair no - 41.20.50
Remove
1.Remove transfer gearbox.See this Section.
2.Remove and discard input shaft oil seal from
transfer gearbox.
Refit
3.Clean oil seal recess in transfer gearbox.
4.Lubricate new oil seal with transfer gearbox oil.
5.UsingLRT-37-014, fit input shaft seal to transfer
gearbox.
6.Fit transfer gearbox.See this Section.
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41TRANSFER GEARBOX
12
REPAIR
10.Fit new seal usingLRT-41-012.
NOTE: Use end of tool marked’REAR’to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit and tighten new drive
flange nut to148 Nm (109 lbf.ft).
13.Position brake drum and tighten screw.
14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then
back off 1 1/2 turns.
15.Check that brake drum is free to rotate.
16.Fit propeller shaft.See PROPELLER SHAFTS,
Repair.
17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING
Service repair no - 41.20.55
Remove
1.Drain transfer gearbox oil.See
MAINTENANCE ,
2.Remove rear output shaft seal.See this
Section.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
5.Clean output shaft housing, mating face on main
casing and sealant from bolt threads.
6.Apply Hylosil RTV 102 to mating flange on
output shaft housing.
7.Fit output shaft housing to main casing ensuring
that splines of output shaft are engaged in
differential.
8.Apply Loctite 290 to bolt threads.
9.Fit bolts and tighten by diagonal selection to45
Nm (33 lbf.ft).
10.Fit rear output shaft seal.See this Section.
11.Fill transfer gearbox with oil.See
MAINTENANCE ,
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PROPELLER SHAFTS
1
REPAIR PROPELLER SHAFT - FRONT
Service repair no - 47.15.02
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
NOTE: To remove the underbelly panel,
the propeller shaft has to be released from
the front differential flange.
2.Mark propeller shaft to transfer gearbox.
3.Remove 4 nuts securing propeller shaft to
transfer gearbox flange.
4.Remove propeller shaft.
Refit
5.Clean propeller shaft flanges and mating faces.
6.Position propeller shaft to transfer gearbox
flange and tighten nuts to48 Nm (35 lbf.ft).
7.Fit underbelly panel.See CHASSIS AND
BODY, Repair.PROPELLER SHAFT - REAR
Service repair no - 47.15.03
Remove
1.Raise rear of vehicle.
WARNING: Support on safety stands.
2.Using a centre punch, mark relationship of
propeller shaft flanges.
3.Remove 4 nuts securing propeller shaft to park
brake flange.
NOTE: Rotation of propeller shaft may be
required during the above procedure.
4.Remove 4 nuts and bolts securing propeller
shaft to rear axle flange.
NOTE: Rotation of propeller shaft may be
required during the above procedure.
5.Release propeller shaft from park brake.
6.Remove propeller shaft.
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