1999 LAND ROVER DEFENDER gearbox

GENERAL SPECIFICATION DATA
7
INFORMATION SHOCK ABSORBERS
Type Telescopic, double-acting non-adjustable.................................................................................
Bore diameter 35.47mm...................................................................
BRAKES
Front brake
Caliper AP Lockheed, four opposed pistons..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc 90 - Solid, outboard, 110/130 - Ventilated, outboard..................................................................................
Disc diameter 298 mm (11.73 in)...................................................................
Disc thickness 90 - 14,1 mm (0.56in), 110/130 - 24mm (0.95 in)..................................................................
Wear limit 1 mm (0.04in) per side of disc.........................................................................
Disc run-out maximum 0,15mm (0.006 in).....................................................
Pad area 58 cm
2(9.0 in2) ..........................................................................
Total swept area 801,3 cm2(124.2 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness 3 mm (0.12in)...................................................
Rear brake
Caliper AP Lockheed opposed piston..............................................................................
Operation Hydraulic, self adjusting.........................................................................
Disc Solid, outboard..................................................................................
Disc diameter 90 - 290 mm (11.42 in), 110/130 - 298 mm (11.73)...................................................................
Disc thickness 90 - 12,5 mm (0.49 in), 110/130 - 14,1 mm (0.56 in)..................................................................
Wear limit 90 - 0,38 mm (0.015 in), 110/130 - 1,0 mm (0.04 in).........................................................................
per side of disc
Disc run-out maximum 0,15 mm (0.006 in).....................................................
Pad area 90 - 30,5 cm
2(4.37 in2), 110/130 - 36,2 cm2(5.61 in2) ..........................................................................
Total swept area 90 - 694 cm2(106.98 in2) ...............................................................
Pad material Ferodo 3440 non asbestos.....................................................................
Pad minimum thickness UP TO 02MY - 3 mm (0.12 in)...................................................
Pad minimum thickness From 02MY - 2 mm (0.08 in)...................................................
Parking brake
Type Mechanical, cable operated drum brake on the rear of.................................................................................
the transfer gearbox output shaft
Drum internal diameter 254 mm (10.0 in).....................................................
Width 70 mm (2.75 in)................................................................................
Pad material Ferodo 3611 non asbestos.....................................................................
Servo/master cylinder
Manufacturer Lucas....................................................................
Servo type LSC 80........................................................................
Master cylinder type 25,4 mm (1.0 in) diameter, tandem.........................................................
Pressure reducing valve, failure conscious Cut-in pressure, 90 - 24 bar (360 Ibf/in
2) ratio 4.0:1, ......................
110 - 43 bar (645 Ibf/in2) ratio 2.9:1*
NOTE: * Pressure reducing valves are not fitted to all 110 specifications.
ProCarManuals.com

LUBRICANTS, FLUIDS AND CAPACITIES
1
INFORMATION RECOMMENDED LUBRICANTS AND FLUIDS
All climates and conditions
AMBIENT TEMPERATURE°C
COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50
Td5ACEA A1 5W/30, 5W/40
Engine sump and B1 5W/50
Manual gearbox Texaco MTF94
Final drive units Molytex EP90 EP90
Swivel pin housings Texaco EP00 EP00
Power steering ATF Dexron IID,
or III
Texaco cold climate
PAS fluid 14315
Transfer box Texaco Multigear 75W-90R
LT230TE
ProCarManuals.com

LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil - Td5 7.20...................................................... 12.67
Extra when refilling after fitting new filter 1.00.......................... 1.76
Manual gearbox 2.38............................................................... 4.19
Transfer gearbox oil 2.30......................................................... 4.00
Front differential 1.70............................................................... 3.00
Rear differential
90 Models 1.70............................................................... 3.00
110 Models 2.26............................................................. 4.00
Power steering box and reservoir LHD 2.90............................ 5.00
Power steering box and reservoir RHD 3.40............................ 6.00
Swivel pin housing oil/grease (each) 0.35................................ 0.60
Fuel tank usable fuel
90 Models 60.00............................................................... 13.20 gall
110 & 130 Models 75.00................................................... 16.50 gall
Cooling system - Td5 13.00....................................................... 22.88
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).
Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 50% otherwise
damage to the engine is liable to occur.
Also, anti-freeze content should not exceed 60%
as this will greatly reduce the cooling effect of the
coolant.RECOMMENDED FUEL
Diesel fuel oil, distillate, diesel fuel, automotive gas or
Derv to British standard 2869, Class A1 or A2
Using diesel fuel with a class rating lower than stated
above could seriously impair vehicle performance.
ProCarManuals.com

10 - MAINTENANCE
CONTENTS
Page
MAINTENANCE
UNDERBONNET VIEW - Td5 1..............................................................................
SEATS AND SEAT BELTS 2..................................................................................
LAMPS, HORNS AND WARNING INDICATORS 2................................................
WIPERS AND WASHERS 3...................................................................................
HANDBRAKE 3.......................................................................................................
BATTERY CONDITION - Td5 4..............................................................................
HANDSET BATTERY 5...........................................................................................
HEADLAMP ALIGNMENT 5....................................................................................
ROAD WHEELS 6...................................................................................................
TYRE PRESSURES, CONDITION AND TREAD DEPTH 6....................................
BRAKE PADS, CALIPERS AND DISCS 7..............................................................
ROAD WHEEL SPEED SENSOR HARNESS - Td5 7............................................
FUEL FILTER ELEMENT 8.....................................................................................
FUEL FILTER SEDIMENTER - Td5 8.....................................................................
INTERCOOLER / COOLING SYSTEM 9................................................................
AMBIENT AIR PRESSURE (AAP) SENSOR - Td5 9..............................................
DOOR LOCKS AND HINGES 10............................................................................
ENGINE COOLANT 10...........................................................................................
BRAKE FLUID 11....................................................................................................
AIR FILTER ELEMENT AND DUMP VALVE 11.....................................................
AUXILIARY DRIVE BELT 12...................................................................................
PAS FLUID, CLUTCH FLUID AND SCREEN WASHER LEVELS 12.....................
STEERING BOX 13................................................................................................
ENGINE OIL 14.......................................................................................................
CENTRIFUGE ROTOR - Td5 14.............................................................................
FULL FLOW OIL FILTER 15...................................................................................
GEARBOX OIL 15...................................................................................................
TRANSFER BOX OIL 16.........................................................................................
FRONT AND REAR AXLE OIL 17..........................................................................
PROPELLER SHAFTS 18.......................................................................................
CLUTCH PIPES AND UNIONS 18..........................................................................
PAS PIPES AND UNIONS 19.................................................................................
ENGINE, GEARBOX, TRANSFER BOX AND AXLES 19.......................................
EXHAUST SYSTEM 20...........................................................................................
STEERING BOX AND SUSPENSION 20...............................................................
STEERING BALL JOINTS 21.................................................................................
SHOCK ABSORBERS 22.......................................................................................
TOWING BRACKET 22...........................................................................................
ENGINE AND TRANSMISSION MOUNTINGS 23..................................................
ProCarManuals.com

MAINTENANCE
15
MAINTENANCE FULL FLOW OIL FILTER
1.Renew full flow oil filter.See ENGINE , Repair.GEARBOX OIL
WARNING: Avoid excessive skin contact
with used gearbox oil. Used gearbox oil
contains potentially harmful contaminants
which may cause skin cancer or other serious
skin disorders.
1.Renew gearbox oil.See MANUAL GEARBOX,
Adjustment.
ProCarManuals.com

MAINTENANCE
19
MAINTENANCE PAS PIPES AND UNIONS
Check
1.Check PAS pipes for correct, secure routing and
signs of chafing.
2.Check for signs of fluid leakage from PAS pump,
hoses, and hose unions.ENGINE, GEARBOX, TRANSFER BOX AND AXLES
Check
1.Check for oil leaks from engine, gearbox, tansfer
box, and front and rear axles. Pay particular
attention to areas around oil seals.
ProCarManuals.com

MAINTENANCE
23
MAINTENANCE ENGINE AND TRANSMISSION MOUNTINGS
1.Check condition of front LH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
2.Check condition of front RH engine mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
3.Check condition of rear LH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.
4.Check condition of rear RH gearbox mounting.
Tighten fixings if necessary.See ENGINE ,
Repair.ROAD TEST
There are two purposes for conducting a road test.
Firstly, to ensure the work completed within the
dealership meets the standards required as layed
down by dealership processes. Secondly, for a skilled
technician to assess the general condition of the
vehicle and report any conditions that the customer
should be made aware of.
CAUTION: Two wheel roller tests must not
be carried out. Four wheel roller tests
must be restricted to 3 mph (5 kph).
1.Check for correct operation of starter switch.
Ensure the engine starts in a correct manner.
Leave the engine running.
2.With vehicle stationary, turn steering from lock to
lock. Check for smooth operation and ensure
there is no undue noise from the power steering
pump or drive belt.
3.Depress clutch and select all gears in turn.
Check for smooth notch free engagement.
4.Drive vehicle on a short road test. Check all
vehicle systems for correct operation. Pay
particular attention to:
Engine noise
Gearbox noise
Suspension noise
Body noise
Braking system operation
Gear selection
Engine performance
5.Check for correct operation of all instruments
and warning devices where practical.
6.After road test, carry out a final inspection of the
vehicle on vehicle ramps.
7.Check all underbonnet fluid levels and top-up if
necessary.
ProCarManuals.com

12 - ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
TD5 ENGINE 1........................................................................................................
GENERAL 12..........................................................................................................
CYLINDER BLOCK 13............................................................................................
CRANKSHAFT, SUMP AND OIL PUMP 22............................................................
CYLINDER HEAD COMPONENTS 25...................................................................
CAMSHAFT COVER COMPONENTS 30...............................................................
CAMSHAFT TIMING CHAIN COMPONENTS 30...................................................
CYLINDER BLOCK FLOW 32.................................................................................
OIL COOLER / FILTER FLOW 34...........................................................................
CYLINDER HEAD FLOW 36...................................................................................
ADJUSTMENT
ENGINE OIL PRESSURE CHECK 1......................................................................
REPAIR
CAMSHAFT 1.........................................................................................................
PULLEY - CRANKSHAFT 3....................................................................................
OIL SEAL - CRANKSHAFT - REAR 4.....................................................................
BEARING - SPIGOT - CRANKSHAFT 5.................................................................
GASKET - CYLINDER HEAD 6..............................................................................
ROCKER SHAFT ASSEMBLY 11...........................................................................
GASKET - COVER - CAMSHAFT 13......................................................................
ENGINE AND ANCILLARIES 14.............................................................................
MOUNTING - FRONT - LH 19................................................................................
MOUNTING - FRONT - RH 20................................................................................
MOUNTING - GEARBOX - REAR - LH 21..............................................................
MOUNTING - GEARBOX - REAR - RH 22.............................................................
FLYWHEEL 22........................................................................................................
FILTER - OIL 23......................................................................................................
STRAINER - OIL PICK-UP 24.................................................................................
PUMP - OIL 24........................................................................................................
GASKET - ENGINE TO SUMP 26..........................................................................
SWITCH - OIL PRESSURE 28...............................................................................
VALVE - RELIEF - OIL PRESSURE 29..................................................................
COOLER - ENGINE OIL 29....................................................................................
CENTRIFUGE ASSEMBLY 30................................................................................
ROTOR - CENTRIFUGE 32....................................................................................
ProCarManuals.com