1999 LAND ROVER DEFENDER weight

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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37MANUAL GEARBOX
10
REPAIR
34.Pull handbrake cable through heel board.
35.Disconnect multiplug from speed sensor and
release harness from clip on transfer gearbox.
36.Remove retaining nut and release battery earth
lead from transfer gearbox.
37.Release body harness clips from bracket on top
of transfer gearbox.
38.Lower gearbox jack sufficiently to allow transfer
gearbox lever to clear tunnel.
39.Disconnect 2 Lucars from differential lock switch,
multiplug from reverse light switch and multiplug
from low ratio detect switch - if fitted and release
multiplug from bracket.
40.Remove bolt and release earth leads from RH
side of transfer gearbox.
41.Support the weight of the engine.
42.Remove 6 bolts securing clutch housing to
engine.
43.With assistance, remove gearbox from engine.
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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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REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect shock absorbers.
6.Disconnect flexible brake hose at RH chassis
side member and breather hose at banjo
connection on axle casing.
7.Disconnect lower links at axle.8.Mark differential and propeller shaft flanges with
identification marks for assembly.
9.Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.If applicable, remove anti-roll bar links at axle
See REAR SUSPENSION, Repair. anti-roll
bar.
14.Remove axle assembly.
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FRONT AXLE AND FINAL DRIVE
1
REPAIR FRONT AXLE ASSEMBLY
Service repair no - 54.10.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets .
Refit bolts to prevent oil leakage.
9.Remove bolts from brake calipers and tie to one
side.
10.Remove nuts and washers securing shock
absorbers to axle.
11.Disconnect drag link from swivel pin housing
arm.
12.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
13.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
14.Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
15.Disconnect anti-roll bar linkSee FRONT
SUSPENSION, Repair. Anti-roll bar ball.
16.Remove axle assembly.
Refit
17.Position axle under vehicle, supporting left side
of axle, and fit anti-roll bar linksSee FRONT
SUSPENSION, Repair. Anti-roll bar links.
18.Fit propeller shaft. Tighten bolts to47 Nm (35
lbf/ft).
19.Fit panhard rod to axle bracket. Tighten bolts to
88 Nm (65 lbf/ft).
20.Fit drag link to swivel pin arm. Tighten fixings to
40 Nm (30 lbf/ft).
21.Fit shock absorbers to axle.
22.Fit brake calipers. Tighten bolts to82 Nm (60
lbf/ft).
23.Tighten upper swivel pin bolts to78 Nm (58
lbf/ft).
24.Fit radius arms to axle brackets. Tighten bolts to
197 Nm (145 lbf/ft).
25.Fit steering damper to track rod.
26.Fit radius arms to chassis side member. Tighten
fixings to197 Nm (145 lbf/ft).
27.Tighten track rod end to40 Nm (30 lbf/ft)and fit
new split pin.
28.Remove chassis supports, fit road wheels and
tighten to correct torque:
Alloy wheels -130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
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76CHASSIS AND BODY
8
REPAIR LINER - FRONT WHEEL ARCH
Service repair no - 76.10.48
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove front wheel.
3.Support axle weight with jack.
4.Remove 6 screws securing damper top cover to
inner wing, remove cover.
5.Remove nut securing damper to top mounting
bracket and collect rubber bush and 2 washers.
6.Remove 4 nuts securing damper to mounting
bracket and collect washers.
7.Remove damper top cover.
8.Remove 4 screws and 3 studs securing liner to
inner wing. Remove liner.
Refit
9.Position liner, secure with screws and studs.
10.Fit damper mounting bracket and tighten nuts.
11.Position damper to mounting bracket, fit rubber
bush and washers and tighten nut.
12.Fit damper cover to inner wing and secure with
screws.
13.Fit road wheel.
14.Remove stands and lower vehicle.
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77PANEL REPAIRS
4
SEALING AND CORROSION PROTECTION APPLICATION EQUIPMENT
SATA Schutz Gun Model UBE
Specifications:
Air consumption 200 litres/min. (7 ft
3/min.) @ 45 psi ...............................................................
Weight 660grams (23.3oz)..............................................................................
Manufactured and supplied by:
Sata Gmbh
Minden Industrial Ltd.
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk IP32 7DX
Tel. (01284) 760791
The Sata Schutz Gun is approved for the re-treatment
of vehicle underbody areas with protective coatings as
supplied in 1-litre (1.76pt.), purpose-designed,
’one-way’containers. The screw thread fitting (female
on the gun) will fit most Schutz-type packs.
Full operating details are supplied with the equipment.
NOTE: Always clean gun after use with the
appropriate solvent.
Sata HKD1 Wax Injection Equipment
The Sata HKD1 is approved by Land Rover for use in
all cavity wax re-treatment operations. The equipment
comprises a high quality forged gun with 1-litre
capacity pressure feed container, a flexible nylon
lance, 1100 mm (43.3 in) straight steel lance and
hooked wand lance. A quick-change coupling is a
standard fitting to enable lances to be easily
interchanged. The lances each have their own spray
pattern characteristics to suit the type of box section
to be treated.
The Sata HKD1 is covered by a 12 month warranty.
All replacement parts and service are obtainable from
the suppliers.
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PANEL REPAIRS
5
SEALING AND CORROSION PROTECTION Cooper Pegler Falcon Junior Pneumatic (Airless)
Manufacturer and supplier:
Cooper Pegler & Co. Ltd.
Burgess Hill
Sussex RH15 9LA
Tel. 04 446 42526
Intended primarily for applying transit wax, the Falcon
Junior pneumatic sprayer has a 5-litre (1 gal.)
container with integral hand pump. This high quality
unit provides a simple and effective means of wax
spraying without the need for compressed air or
additional services.
A selection of nozzles, lances and hoses together with
a trigger valve assembly incorporating a filter enable
the sprayer to be used in a variety of applications.
These include general maintenance, wax injection and
paint application. All parts are fully replaceable and
include a wide range of nozzle configurations.
The Falcon Junior is fitted with Viton seals and is
guaranteed for 12 months.3M Application Equipment
Manufacturer:
3M UK PLC
Automotive Trades Group
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. (01344) 858611
All 3M equipment is available from local trade factors
or 3M refinishing factors.
3M Caulking Gun 08002
A lightweight, robust metal skeleton gun designed to
accommodate 325 mm (12.8 in) cartridge for
dispensing sealants etc. This gun facilitates rapid
cartridge loading and features a quick-release lever
for accurate material ejection and cut-off control.
3M Pneumatic Cartridge Gun 08012
An air line fed gun for application of 3M cartridge
products. Excellent ease of application for a smooth
sealant bead, and incorporates a regulator valve for
additional control.
Other 3m applicator equipment available:
3M Pneumatic Applicator Guns
Air line fed gun for application of 3M sachet sealers
(Part No. 08006 for 200 ml (6 fl oz) and 310 ml (9 fl
oz) sachets, and Part No. 08007 for all size sachets
including 600 ml (18 fl oz).
3M Applicator Gun 08190
For application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun
Features 750 mm (29.6 in) flexible tube and using
1-litre (1.76 pt) canisters, this approved equipment is
available from all 3M refinishing factors.
Other 3m applicator equipment available:
Heavy Duty Manual Gun.
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