1999 LAND ROVER DEFENDER gearbox

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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MANUAL GEARBOX
3
REPAIR LEVER - GEAR CHANGE
Service repair no - 37.16.04
Remove
1.Remove gear lever knob.
2.Release and remove gear lever gaiter(s).
3.Remove nut securing upper gear lever to lower
gear lever.
4.Remove upper gear lever from lower gear lever.
5.Using a suitable piece of tubing fitted over end of
bias spring, release both ends of bias spring
from ball pins.
6.Remove bolt and special washer securing gear
lever to housing.
7.Carefully withdraw gear lever from housing
ensuring that spring loaded nylon pad is retained
during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
Refit
8.Clean gear lever, housing and nylon pad.
9.Lubricate ball pin with multi-purpose grease and
fit nylon pad and spring.
10.Depress nylon pad against spring pressure,
position gear lever in housing with the nylon pad
facing away from bias spring location.
11.Fit gear lever retaining bolt and special washer
and tighten bolt to10 Nm (7 lbf.ft).
12.Using a suitable piece of tubing fitted over ends
of bias spring, locate each end of bias spring to
ball pins.
13.Fit upper gear lever to lower gear lever and
tighten retaining nut to25 Nm (18 lbf.ft).
14.Adjust bias spring.See Adjustment.
15.Fit gear lever gaiter(s).
16.Fit gear lever knob.
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37MANUAL GEARBOX
4
REPAIR MECHANISM AND HOUSING - GEAR SELECTOR
Service repair no - 37.16.37
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever gaiter(s)
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Remove 4 bolts securing gear change housing,
remove housing, remove and discard gasket.
10.Using a suitable piece of tubing located over
ends of bias spring, release both ends of bias
spring from ball pins.
11.Loosen locknuts and remove bias spring
adjusting screws.
12.Drift out roll pin, remove bias spring.
13.Remove nut and extension from lower gear
lever.
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MANUAL GEARBOX
5
REPAIR
14.Remove bolt and special washer securing lower
gear lever in housing.
15.Carefully withdraw lower gear lever from the
housing ensuring that the spring loaded nylon
pad is retained during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
16.Release nylon pad, recover spring.
Refit
17.Clean components, gear change housing and
mating face on remote housing.
18.Apply multi - purpose grease to ball pin and fit
spring and nylon pad.
19.Depress nylon pad against spring pressure,
position lower gear lever in housing with the
nylon pad facing away from bias spring location.
20.Fit lower gear lever retaining bolt and special
washer and tighten bolt to10 Nm (7 lbf.ft).
21.Fit upper gear lever to lower gear lever and
tighten nut to25 Nm (18 lbf.ft).
22.Drift new roll pin into housing.
23.Fit bias spring adjusting screws and locknuts.
24.Using a suitable piece of tubing, locate both
ends of bias spring over ball pins.
25.Fit new gasket to remote housing, position gear
change housing to remote housing and tighten
bolts to25 Nm (18 lbf.ft).26.Adjust bias springs.See Adjustment.
27.Fit and align tunnel cover, fit and tighten screws.
28.Secure bulkhead carpet to LH side of tunnel.
29.Position relay/fuse panel, fit spacers and tighten
screws.
30.Fit insulation pad around gear levers.
31.Fit gear lever gaiter(s).
32.Fit gearbox tunnel carpet.
33.Fit gear lever knobs.
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37MANUAL GEARBOX
6
REPAIR MECHANISM AND HOUSING - GEAR SELECTOR -
RESEAL
Service repair no - 37.16.37.01
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever gaiter(s).
4.Release and remove insulation pad from around
gear levers.
5.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6.Release bulkhead carpet from LH side of tunnel
and move aside.
7.Remove 13 screws securing tunnel cover.
8.Release and remove tunnel cover.
9.Remove 4 bolts securing gear change housing,
remove housing, remove and discard gasket.
Refit
10.Clean gear change housing and mating face on
remote housing.
11.Fit new gasket to remote housing, position gear
change housing to remote housing; fit bolts and
tighten to25 Nm (18 lbf.ft).
12.Fit and align tunnel cover, fit and tighten screws.
13.Secure bulkhead carpet to LH side of tunnel.
14.Position relay/fuse panel, fit spacers and tighten
screws.
15.Fit insulation pad around gear levers.
16.Fit gear lever gaiter(s).
17.Fit gearbox tunnel carpet.
18.Fit gear lever knobs.
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MANUAL GEARBOX
7
REPAIR GEARBOX
Service repair no - 37.20.02.99
Remove
1.Disconnect battery negative lead.
2.Remove gear lever and transfer gearbox lever
knobs.
3.Remove gearbox tunnel carpet.
4.Remove gear lever cover.
5.Remove nut and washer securing gear lever to
lower splined lever.
6.Mark gear lever spline setting to lower lever and
remove lever.
7.Release and remove insulation pad from tunnel.
8.Remove trim stud and lift up handbrake gaiter for
access to clevis pin.
9.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever; discard
split pin.
10.Remove 2 bolts securing hand-brake lever to
body, disconnect Lucar and remove lever.
11.Remove 2 screws securing relay panel and
collect 2 spacers.
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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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