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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

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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. 
    						
    							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. 
    						
    							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. 
    						
    							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. 
    						
    							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. 
    						
    							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. 
    						
    							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. 
    						
    							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.................................................................................. 
    						
    							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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