1999 LAND ROVER DEFENDER gearbox

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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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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37MANUAL GEARBOX
12
REPAIR SWITCH - REVERSE LIGHT
Service repair no - 37.27.01
Remove
1.Remove gear lever knobs.
2.Remove gearbox tunnel carpet.
3.Remove gear lever (s) gaiter.
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.Disconnect reverse light switch multiplug.
10.Remove switch and discard sealing washer.
Refit
11.Clean switch and mating face on gearbox.
12.Fit new sealing washer and fit switch to gearbox.
13.Connect reverse light switch multiplug.
14.Fit and align tunnel cover, fit and tighten screws.
15.Secure bulkhead carpet to LH side of tunnel.
16.Position relay/fuse panel, fit spacers and tighten
screws.
17.Fit insulation pad around gear levers.
18.Fit gear lever (s) gaiter.
19.Fit gearbox tunnel carpet.
20.Fit gear lever knobs.
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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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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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41TRANSFER GEARBOX
2
ADJUSTMENT
12.Remove clevis pin clip and clevis pin securing
high-low selector linkage to lever.
13.Select neutral in transfer gearbox.
14.Move gear lever to neutral position.
15.Align linkage and check that clevis pin passes
through linkage without binding.
16.If binding occurs, adjust linkage until clevis pin
passes through without binding.
17.Fit clevis pin and clevis pin clip.
18.Tighten locknut.
19.Fit and align tunnel cover and secure with
screws.
20.Position hand-brake lever and tighten bolts to25
Nm (18 lbf.ft).
21.Secure bulkhead carpet to LH side of tunnel.
22.Position relay/fuse panel, fit spacers and tighten
screws.
23.Position insulation pad around gear levers.
24.Fit gear lever gaiter.
25.Fit gearbox tunnel carpet.
26.Fit gear lever knobs.
27.Reconnect battery negative lead.
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TRANSFER GEARBOX
1
REPAIR BOTTOM COVER - TRANSFER GEARBOX -
RESEAL
Service repair no - 41.20.06
1.Raise vehicle on ramp.
2.Remove 6 bolts securing rear underbelly panel
and remove panel.
3.Drain transfer gearbox oil.
4.Remove 10 bolts securing bottom cover to
transfer gearbox and remove cover.
Refit
5.Clean bottom cover and mating face on transfer
gearbox.
6.Clean bolt threads.
7.Apply Loctite 290 to bolt threads.
8.Apply Hylosil RTV sealant to bottom cover
sealing face.
9.Position bottom cover, fit bolts and tighten to25
Nm (18 lbf.ft).
10.Fill transfer gearbox with oil.
11.Fit rear underbelly panel and tighten bolts.
12.Lower vehicle on ramp.TRANSFER GEARBOX
Service repair no - 41.20.25.99
Remove
1.Position vehicle on a’4 post’ramp
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Select low range gear and leave vehicle in
neutral.
5.Remove gear lever knobs.
6.Remove gearbox tunnel carpet.
7.Remove gear lever cover.
8.Release and remove insulation pad.
9.Remove cubby box.See CHASSIS AND
BODY, Repair.
10.Remove 4 screws securing access panel,
diagnostic plug mounting bracket and place
aside.
11.Remove trim stud and lift up handbrake gaiter for
access to clevis pin.
12.Remove split pin, washer, clevis pin and
disconnect cable from handbrake lever.
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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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