Land Rover Defender 90 110 Workshop Book 8 Bulletins Rover

							TRANSMISSION I37 
7. Check  that a minimum  clearance of 1,Omm 
exists between  the front face of the reverse 
idler gear  and the  rear  face of the reverse  gear 
on  the 
firstkecond synchromesh  sleeve. If the 
clearance 
is insufficient,  adjust the cross-over 
lever  again. 
8. Return  the firstkecond selector  rail back  to 
neutral. 
9. Remove  the  detent  spring retaining  tool and 
spacers 
Gearbox top cover. 
1. Fit  the  top  cover  gasket. 
2. Fit the top cover locating  it over  the  detent 
springs. 
3. Position  the breather  pipe,  locate  retaining 
clips  and secure  the top  cover  with the eight 
bolts  and  spring  washers. 
4. Fit the breather pipe banjo  union  and fibre 
washers. 
5. Fit  the  reverse  light switch. 
6. Place  clean  rag in top cover  gear lever 
aperature 
to prevent  the entry of dirt. 
lower  gear  lever and bias spring housing 
1. Remove  the rag from  gearbox  top cover. 
2. Lubricate  and fit the  gear  lever  ball lower yoke 
3. Fit a new  gasket  to the  housing. 
4. Fit the  rubber  grommet. 
5. Apply grease to the bias  springs. 
6. Fit the  shims  and bias  springs,  followed by the 
7. Secure  with the four  set screws  and spring 
and  nylon 
cup. 
spring  housing. 
washers. 
a 
6 
31  
						

							TRANSMISSION 
Bell housing. 
1. Fit a new bell housing  gasket. 
2. Locate the bell  housing  squarely  on the 
dowels  and secure  to the  gearbox  with the 
six 
bolts  and  spring washers. 
Gearbox  extension  housing. 
1. Remove the gearbox  assembly  from the vice 
and  detach  the stand. 
2. The  special  nut  retaining  the fifth  gear  to the 
layshaft  must be secured  by  carefully  forming 
the  collar 
of the nut  into  the layshaft  slots, as 
illustrated. 
CAUTION: A round nose tool must  be used for 
this  operation  to avoid  splitting  the coller of the 
nut. 
Also, the layshaft  fifth gear should  be 
supported  by a block 
of timber  whilst the nut is 
being  deformed  to prevent  damage 
to the 
adjacent  bearing. 
3. Support the underside of the gearbox  with  a 
block 
of timber. 
4. Lubricate  the oil seal protection  sleeve  LST 
102 and insert it into  the oil seal from  inside 
the  extension  housing. 
5. Fit a new  gasket  to the  extension  housing. 
6. Carefully slide the extension  housing, with the 
seal  protection  sleeve  in position,  over the 
mainshaft  and locate  on the  dowels. 
7. Withdraw  the oil seal protection sleeve. 
8. Secure  the extension  housing with the eight 
bolts,  spring  washers  and single  nut.  The 
illustration  below shows  the correct  length 
of 
bolt for each of the eight  locations. 
60 
45f 
0 
I6O Ic .. 
ST 2067M 45 
32  
						

							. ..h ... .. : :;; ::::;  j;, c.  . _._,, ... 
TRANSMISSION 137 
Third/fourth selector rail adjustment 7. Unscrew  the stop bolt. 
8. Select fourth gear  and  screw-in the  stop  bolt 
until  contact 
is made  with the third/fourth 1. Slacken  the third/fourth stop screw  in the 
extension  housing.  selector  shaft. 
2. Select third gear. 
3. Tighten the stop  screw untilit makes  contact 
with  the 
third/fourth selector  rail. 
4. Turn back  the stop  screw one turn. 
5. Return  the gear  lever  to the  neutral  position. 
6. Slacken  the locknut  on the third/fourth stop 
bolt  inside  the bell  housing. 
9. Turn back  the stop  bolt one turn  and tighten 
the  locknut. 
10. Return  the gear  lever  to the  neutral  position. 
Bias  spring  adjustment. 
1. Apply Loctite  stud  and  bearing fit 270 to the 
bias  spring  screws  and  turn  the screws 
clockwise  until the heads  are flush  with  the 
top  face 
of the bias  spring  housing. 
ST 
Gearbox mounting 
1. Fit the  mounting  to the  extension  housing and 
. secure with the four  bolts. 
33  
						

							I I 
Range Land  Rover Rover Workshop Bulletin 
.r- AIJENTION SERVICE  MANAGER . . .: 5. , 
FEBRUARY 1988 
BULLETIN NUMBER SLR621ENWB4 
LAND ROVER 
1988 MODEL IMPROVEMENTS 
Further supplies of this BdIetin can he obtained, free of charge, from: 
Land Rover  Merchandising  Service 
P.O. Box 534, Erdington Birmingham 824 OQS 
SERVICE Land Rover Service  Division  
						

							n 
101 I INTRODUCTION 
INTRODUCTION 
Also included in the 1988 Year  Land  Rover  model 
improvements  are the  following  items which  are 
fully described  to assist  the workshop.  The first 
operation,  whilst not being  part 
of the 
improvement  programme 
is, nevertheless, a 
continuation 
of the  policy  to replace  material 
gaskets,  where practicable,  with liquid  sealants.  The 
opportunity  has, therefore  been taken 
to include,  in 
this  Bulletin,  the latest,  most significant  change 
under  this policy. 
ALL LAND ROVER  FOUR CYLINDER ENGINES 
Rear main  bearing  cap sealing. 
A change  has recently  been introduced  to the 
method 
of sealing  the rear  main  bearing  cap. 
Hitherto  sealing was accomplished  using 
T 
shaped cork packing strips one each  side of the 
cap.  Sealing  is now  achieved  by injecting 
Hylosil 
102 (black)  into the slots  formally  occupied  by the 
packing  strips. This material  may also 
be used on all 
earlier  engines  where the caps  were  sealed  with 
packing  strips. 
The 
1. 
2. 
3. 
method is as follows:- 
With the sump  removed,  fit the  main  bearing 
cap  and tighten  the bolts  to the  correct 
torque,  130
-136 Nm (96- 100 1bf.ft.). 
Turn the crankshaft to bring  numbers  two and 
three  pistons  to 
Top Dead Centre so that the 
crankshaft  webs will not obscure  the rear 
bearing  cap. 
Using  a suitable  applicator,  inject the sealant 
into  the main  bearing  cap slot  adjacent  to the 
bearing  cap 
bolt recess until it emerges  from 
the  upper  end 
of the slot. 
4. 
5. 
Repeat  instruction 3 on the  opposite side of 
the bearing  cap. e.. g. b: , Remove  surplus sealant and fit the  sump. 
Note:  When  removing  surplus sealant from 
the  sump  gasket  face, ensure  that the 
sealant  is cleaned
-off  level  to the  cylinder 
block  machined  face. 
2  
						

							BODY n 76 
SUN ROOF LAND ROVER 9OandllO. 
To remove 
4. Raise-up the  rear of the  panel  and withdraw  it 
rearwards  from the sun 
roof exterior surround. 
1. Open  the  roof panel  to its  fullest  extent by 
pulling  the latch  handle  down to the  first  open 
position. 
5. Remove  the two  screws  and  withdraw the 
latch  finisher. 
2. Then  move  the green  button  to the  right  and 
push  the panel  up as far  as the  latch 
will allow 
to  the  fully  open  position. 
3. Move  the red  button  upwards  and open  the 
retaining  hasp. 
6. The sun roof interior  finisher  is secured  by 
fourteen  dowels 
to the  sun  roof  outer  frame 
retainer. 
To remove  the finisher,  carefully  lever 
the  finisher  away  from the retainer  using  a 
screwdriver  with  a broad blade. 
Continued 
3  
						

							176 I BODY 
7. Remove the fifteen  screws  and withdraw  the 
outer  frame  retainer. 
8. Lift the  sun roof external  frame  from the 
vehicle. 
9. If necessary,  remove the adhesive- backed 
seal, 
from the  inner  edge of the frame,  that 
seals  it 
to the vehicle  roof. 
To refit 
11. If, removed,  fit the  two  centralising  blocks to 
the  outer  frame  and secure  with adhesive. 
10. To release  the latch  from  the glass 
panel,remove the two screws  and  withdraw 
the  latch  and backing  plate. 
12. Secure a new  seal to the  outer  closing  edge 
of the frame  avoiding  a join  along  the hinge 
side. 
Continued 
4  
						

							I: .-...  ,.,.. :.: ., ,_:. ,t:: I . I. ....*. .... I .,. :. 
BODY 76 
ST2 10 1 M v i 
13.  Clean the area of contact  on the  vehicle  roof 
then  Lower  the frame  into position  on the 
roof. 
14. From  inside  the vehicle,  offer-up the  retaining 
frame  and secure  to the  outer  frame with the 
fifteen  screws. 
15. If removed,  fit the  latch to the glass  panel  with 
the  backing  plate and 
two screws,reversing 
instruction 10. 
16. Secure  the interior  finisher to the  retaining 
frame  with the fourteen  dowels. 
17. Fit and secure  the latch  finisher  with the two 
screws. 
18. Fit the  glass  panel  and latch  assembly  squarely 
to the outer  frame. 
19.  Lower  the latch  on 
to the pivot  bar, ensuring 
that  the bar locates 
in its cradle,  and whilst 
pushing  the red  button  upwards, 
close the 
latch  hasp  over  the bar until  it locks  reversing 
instruction 
3. 
* 
20. To check  the operation  and to close the 
pane1,move the green  button  to the  right 
whilst  pulling  the latch  handle  downwards  until 
it  snaps  into the locked  position. 
IANDROVER 1 10 STATION  WAGON. 
Rear side window  trim. 
To remove 
1. To gain access  to the  trim lower fixings 
remove  the rear  seat  and squab  frame 
complete. 
2. Remove  the plastic  cover  and  the seat  belt 
anchorage  bolt from  the 
C post. 
3.  Remove  the 
lower anchorage  bolt for the 
same  seat belt. 
4. Remove  the seat  belt  aperature  finisher  from 
the  trim  panel  and  remove  the rear  quarter 
light  trim from  the 
side concerned. 
Continued 
5  
						

							76 
ST2105M  
BODY 
5. Using  a screwdriver,  carefully lever the trim 
retaining  button from the 
C post.The button 
is held by a fir-tree type  peg. 
ST2 1 07.M 
71 
I 
6 
8. The top edge of the trim is held  to the  inner 
cant  rail by three  spring 
clips.Strike upwards, 
with  the hand, 
as illustrated,  to release  the 
trim. 
STZlO9M 
6. Remove  the trim  lower  three fixings.  The 
forward  fixing 
is a screw, two washers  and a 
nut. 
7. The  rear and centre  fixings are a screw, washer 
and  a nut  welded  to a 
plate.When the  screw  is 
removed  the plate  will  fall  into the boxed 
section 
of the  attachment  side member. 
9. Feed  the seat  belt through  the aperature  and 
remove  the trim  from  the vehicle. 
Continued 
6