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

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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. 
    						
    							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. 
    						
    							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. 
    						
    							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. 
    						
    							41TRANSFER GEARBOX
    4
    REPAIR
    32.Remove retaining nut and release battery earth
    lead from transfer gearbox.
    33.Release body harness clips from bracket on top
    of transfer gearbox.
    34.Lower gearbox jack sufficiently to allow transfer
    gearbox lever to clear tunnel.
    35.Disconnect Lucars from differential lock warning
    lamp switch and multiplug from low ratio detect
    switch, and release multiplug from bracket.
    36.Remove bolt and release earth leads from RH
    side of transfer gearbox.
    37.Move the high/low selector lever upwards to gain
    access to adjacent nut securing transfer gearbox
    to main gearbox.
    38.Position a jack to support main gearbox and
    engine.
    39.Noting their fitted positions, remove 4 bolts
    securing transfer gearbox to main gearbox
    extension case.
    40.Fit 3 guide studsLRT-41-009through transfer
    gearbox bolt holes to support it during during
    removal.
    41.Remove 2 nuts securing transfer gearbox to
    main gearbox extension case.
    CAUTION: If studs are removed during this
    operation, they must be discarded and
    new studs fitted.
    42.With assistance, remove transfer gearbox from
    main gearbox. 
    						
    							TRANSFER GEARBOX
    5
    REPAIR
    43.If transfer gearbox is to be refitted, remove and
    discard input shaft oil seal.
    Refit
    44.Clean mating faces of main gearbox extension
    case and transfer gearbox.
    45.Remove all traces of sealant from threads of
    transfer gearbox securing bolts and studs.
    46.Clean input shaft oil seal recess in transfer
    gearbox.
    47.Lubricate new input shaft oil seal with transfer
    gearbox oil.
    48.Using toolLRT-37-014, fit input shaft oil seal, lip
    side facing inwards.49.Ensure guide studsLRT-41-009are fitted in
    main gearbox extension case.
    CAUTION: If securing studs were removed
    during transfer gearbox removal, apply
    Loctite 290 to threads of new studs; fit
    studs and tighten to 45 Nm (33 lbf.ft).
    50.Secure transfer gearbox to support plate
    LRT-99-010, fit and tighten 4 bolts.
    51.Raise transmission hoist until transfer gearbox
    can be located over guide studsLRT-41-009.
    52.Apply Loctite 290 to threads of securing bolts
    and studs.
    53.Fit and lightly tighten 2 nuts to secure transfer
    gearbox to main gearbox extension case.
    54.Remove guide studsLRT-41-009.
    55.Ensuring bolts are in their original fitted
    locations, fit and lightly tighten 4 bolts to secure
    transfer gearbox to main gearbox extension
    case.
    56.Progressively tighten nuts and bolts to45 Nm
    (33 lbf.ft).
    57.Position earth leads to RH side of transfer
    gearbox, fit and tighten bolt.
    58.Connect low ratio detect switch multiplug and
    secure to bracket. Connect Lucars to differential
    lock warning lamp switch.
    59.Raise gearbox jack and guide transfer gearbox
    lever through tunnel.
    60.Connect body harness clips to bracket on top of
    transfer gearbox.
    61.Position earth lead to transfer gearbox, tighten
    nut to45 Nm (33 lbf.ft).
    62.Connect speed sensor multiplug and secure
    harness in clip.
    63.Position heat shield to LH mounting, fit
    mountings and brackets and tighten bolts to85
    Nm (63 lbf.ft).
    64.Fit nuts securing RH and LH mountings and
    tighten to48 Nm (35 lbf.ft).
    65.Position breather pipe to transfer gear box, fit
    new sealing washers and tighten banjo bolts to
    15 Nm (11 lbf.ft).
    66.Remove bolts securing support plate to gearbox
    jack.
    67.Remove bolts securingLRT-99-010to transfer
    gearbox.
    68.Apply Loctite 290 to threads of bottom cover
    securing bolts, fit bolts and tighten to25 Nm (18
    lbf.ft)
    69.Position differential lock control rod and secure
    with retaining clip.
    70.Clean rear propeller shaft to brake drum flange
    mating faces. 
    						
    							41TRANSFER GEARBOX
    6
    REPAIR 71.Release propeller shaft, align flange markings
    and connect to studs.
    72.Fit nuts securing propeller shaft and tighten to48
    Nm (33 lbf.ft).
    73.Clean front propeller to transfer gearbox flange
    mating faces.
    74.Fit propeller shaft, align flange markings and
    tighten nuts to48 Nm (33 lbf.ft).
    75.Using new gasket, fit intermediate silencer and
    tighten nuts to25 Nm (18 lbf.ft).
    76.Fit exhaust front pipe.See MANIFOLD AND
    EXHAUST SYSTEM, Repair.
    77.Refill transfer gearbox with recommended oil.
    78.Fit cooling fan cowl.
    79.Fit high/low operating rod and secure with
    retaining clip.
    80.Position handbrake outer cable to heelboard.
    81.Position handbrake cable to lever, fit clevis pin,
    washer and new split pin.
    82.Position handbrake gaiter and secure with trim
    studs.
    83.Fit insulation pad to tunnel.
    84.Fit gear lever cover.
    85.Fit gear lever knobs.
    86.Position diagnostic plug bracket, access panel
    and tighten screws.
    87.Fit carpet to transmission tunnel.
    88.Fit cubby box.See CHASSIS AND BODY,
    Repair.
    89.Fit cooling fan.See COOLING SYSTEM,
    Repair.
    90.Reconnect battery negative lead.
    91.Fit battery cover.GASKET - REAR COVER PLATE
    Service repair no - 41.20.30
    Remove
    1.Raise vehicle on’4 post ramp’.
    2.Mark rear cover plate to bearing housing for
    assembly purposes.
    3.Noting fitted position of stud bolt and harness
    clip bracket, remove 5 bolts and stud bolt
    securing cover plate.
    4.Collect harness clip bracket.
    5.Remove cover plate.
    Refit
    6.Clean cover plate and mating face.
    7.Apply Hylosil RTV 102 to rear cover mating face.
    8.Align reference marks, fit cover plate.
    9.Clean cover bolts and apply Loctite 290 threads
    of bolts and stud nut.
    10.Position clip bracket, fit stud nut and bolts,
    tighten by diagonal selection to25 Nm (18
    lbf.ft).
    11.Check/top-up transfer gearbox oil.
    12.Lower vehicle. 
    						
    							TRANSFER GEARBOX
    7
    REPAIR SWITCH - DIFFERENTIAL LOCK WARNING LAMP
    Service repair no - 41.20.34
    Remove
    1.Remove battery cover.
    2.Disconnect battery negative lead.
    3.Remove gear lever knobs.
    4.Remove gearbox tunnel carpet.
    5.Remove gear lever (s) gaiter.
    6.Release and remove insulation pad from around
    gear levers.
    7.Remove 2 screws securing relay/fuse panel and
    collect 2 spacers.
    8.Release bulkhead carpet from LH side of tunnel
    and move aside.
    9.Remove 2 bolts securing hand-brake lever to
    body and move aside.
    10.Remove 13 screws securing tunnel cover.
    11.Release and remove tunnel cover.
    12.Disconnect Lucars from differential lock warning
    lamp switch.
    13.Loosen and remove switch.
    NOTE: Locknut fitted in place of spacer on
    early transfer boxes.
    14.Remove locknut/spacer from switch.
    Refit
    15.Clean switch, locknut/spacer and mating face on
    gearbox.
    16.Fit locknutnut/spacer to switch with counterbore
    on spacer positioned towards switch head.
    NOTE: To ensure that the switch setting is
    correct, make sure the spacer is fully
    tightened to switch head, (no gap). 
    						
    							41TRANSFER GEARBOX
    8
    REPAIR 17.Apply Hylomar PL32 sealant to switch threads.
    18.Position switch into gearbox housing until
    locknut/spacer bottoms out on housing.
    19. Switches fitted with spacer:Tighten spacer
    securing differential lock switch to11 Nm (8
    lbf.ft).
    20.Connect Lucars to switch.
    21. Switches fitted with locknut:Adjust switch.
    See Adjustment.
    22.Fit and align tunnel cover, fit and tighten screws.
    23.Fit hand-brake lever and tighten bolts to25 Nm
    (18 lbf.ft).
    24.Secure bulkhead carpet to LH side of tunnel.
    25.Position relay/fuse panel, fit spacers and tighten
    screws.
    26.Fit insulation pad around gear levers.
    27.Fit gear lever (s) gaiter.
    28.Fit gearbox tunnel carpet.
    29.Fit gear lever knobs.
    30.Reconnect battery negative lead.
    31.Fit battery cover.SEAL - INPUT SHAFT
    Service repair no - 41.20.50
    Remove
    1.Remove transfer gearbox.See this Section.
    2.Remove and discard input shaft oil seal from
    transfer gearbox.
    Refit
    3.Clean oil seal recess in transfer gearbox.
    4.Lubricate new oil seal with transfer gearbox oil.
    5.UsingLRT-37-014, fit input shaft seal to transfer
    gearbox.
    6.Fit transfer gearbox.See this Section. 
    						
    							TRANSFER GEARBOX
    9
    REPAIR SEAL - FRONT OUTPUT SHAFT
    Service repair no - 41.20.51
    Remove
    1.Position vehicle on 4 post ramp.
    2.Remove underbelly panelSee CHASSIS AND
    BODY, Repair.
    3.Mark front propeller shaft to transfer gearbox
    flanges for reassembly purposes.
    4.Remove and discard 4 nuts securing front
    propeller shaft to transfer gearbox drive flange,
    and release propeller shaft from flange.
    5.Restrain transfer gearbox drive flange using
    LRT-51-003, remove and discard drive flange
    nut, remove and discard steel and felt washers.
    6.UsingLRT-99-500if necessary remove drive
    flange from transfer gearbox.
    7.Remove and discard front input shaft oil seal
    from transfer gearbox. 
    						
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