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

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    							41TRANSFER GEARBOX
    10
    REPAIR Refit
    8.Clean oil seal recess.
    9.Lubricate new input shaft oil seal with transfer
    gearbox oil.
    10.Fit oil seal usingLRT-41-012.
    NOTE: Use end of tool marked ’FRONT’ to
    fit seal.
    11.Position drive flange, fit new felt and steel
    washers.
    12.PositionLRT-51-003fit new drive flange nut and
    tighten to148 Nm (109 lbf.ft).
    13.Align marks and position front propeller shaft to
    output flange. Fit new nuts and tighten to48 Nm
    (35 lbf.ft).
    14.Fit underbelly panel.See CHASSIS AND
    BODY, Repair.
    15.Check/top-up transfer gearbox oil.SEAL - REAR OUTPUT SHAFT
    Service repair no - 41.20.54
    Remove
    1.Loosen brake shoe adjuster bolt.
    2.Remove rear propeller shaft.See PROPELLER
    SHAFTS, Repair. 
    						
    							TRANSFER GEARBOX
    11
    REPAIR
    3.Remove screw securing brake drum.
    4.Remove brake drum.
    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 rear output shaft oil seal
    from transfer gearbox.
    Refit
    8.Clean seal recess.
    9.Lubricate new oil seal with transfer gearbox oil. 
    						
    							41TRANSFER GEARBOX
    12
    REPAIR
    10.Fit new seal usingLRT-41-012.
    NOTE: Use end of tool marked’REAR’to
    fit seal.
    11.Position drive flange, fit new felt and steel
    washers.
    12.PositionLRT-51-003fit and tighten new drive
    flange nut to148 Nm (109 lbf.ft).
    13.Position brake drum and tighten screw.
    14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then
    back off 1 1/2 turns.
    15.Check that brake drum is free to rotate.
    16.Fit propeller shaft.See PROPELLER SHAFTS,
    Repair.
    17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING
    Service repair no - 41.20.55
    Remove
    1.Drain transfer gearbox oil.See
    MAINTENANCE ,
    2.Remove rear output shaft seal.See this
    Section.
    3.Mark output shaft housing to main casing for
    assembly purposes.
    4.Note position of shoulder bolt, remove 6 bolts
    securing housing to main casing.
    Refit
    5.Clean output shaft housing, mating face on main
    casing and sealant from bolt threads.
    6.Apply Hylosil RTV 102 to mating flange on
    output shaft housing.
    7.Fit output shaft housing to main casing ensuring
    that splines of output shaft are engaged in
    differential.
    8.Apply Loctite 290 to bolt threads.
    9.Fit bolts and tighten by diagonal selection to45
    Nm (33 lbf.ft).
    10.Fit rear output shaft seal.See this Section.
    11.Fill transfer gearbox with oil.See
    MAINTENANCE , 
    						
    							TRANSFER GEARBOX
    13
    REPAIR SWITCH - LOW DETECT
    Service repair no - 41.30.05
    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 lever aside.
    10.Remove 13 screws securing tunnel cover.
    11.Release and remove tunnel cover.12.Release switch multiplug from bracket on
    transfer gearbox, disconnect from harness.
    13.Remove switch.
    Refit
    14.Clean switch and mating face on transfer
    gearbox.
    15.Fit nut/spacer to switch with counterbore
    positioned towards switch head.
    16.Apply Hylomar PL32 sealant to switch threads.
    17.Fit switch and tighten to24 Nm (19 lbf.ft).
    18.Connect multiplug to harness.
    19.Fit and align tunnel cover, fit and tighten 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.Fit insulation pad around gear levers.
    24.Fit gear lever (s) gaiter.
    25.Fit gearbox tunnel carpet.
    26.Fit gear lever knobs.
    27.Reconnect battery negative lead.
    28.Fit battery cover. 
    						
    							41TRANSFER GEARBOX
    14
    REPAIR 
    						
    							47 - PROPELLER SHAFTS
    CONTENTS
    Page
    REPAIR
    PROPELLER SHAFT - FRONT 1...........................................................................
    PROPELLER SHAFT - REAR 1..............................................................................
    OVERHAUL
    PROPELLER SHAFT - FRONT 1...........................................................................
    PROPELLOR SHAFT - REAR 2............................................................................. 
    						
    							PROPELLER SHAFTS
    1
    REPAIR PROPELLER SHAFT - FRONT
    Service repair no - 47.15.02
    Remove
    1.Remove underbelly panel.See CHASSIS AND
    BODY, Repair.
    NOTE: To remove the underbelly panel,
    the propeller shaft has to be released from
    the front differential flange.
    2.Mark propeller shaft to transfer gearbox.
    3.Remove 4 nuts securing propeller shaft to
    transfer gearbox flange.
    4.Remove propeller shaft.
    Refit
    5.Clean propeller shaft flanges and mating faces.
    6.Position propeller shaft to transfer gearbox
    flange and tighten nuts to48 Nm (35 lbf.ft).
    7.Fit underbelly panel.See CHASSIS AND
    BODY, Repair.PROPELLER SHAFT - REAR
    Service repair no - 47.15.03
    Remove
    1.Raise rear of vehicle.
    WARNING: Support on safety stands.
    2.Using a centre punch, mark relationship of
    propeller shaft flanges.
    3.Remove 4 nuts securing propeller shaft to park
    brake flange.
    NOTE: Rotation of propeller shaft may be
    required during the above procedure.
    4.Remove 4 nuts and bolts securing propeller
    shaft to rear axle flange.
    NOTE: Rotation of propeller shaft may be
    required during the above procedure.
    5.Release propeller shaft from park brake.
    6.Remove propeller shaft. 
    						
    							47PROPELLER SHAFTS
    2
    REPAIR Refit
    7.Grease propeller shaft universal joints.
    8.Grease propeller shaft spline.
    9.Clean propeller shaft flange mating faces.
    10.Fit propeller shaft to park brake flange bolts.
    NOTE: Ensure relationship marks align.
    11.Position propeller shaft to rear axle flange and fit
    bolts.
    12.Fit nuts and bolts securing propeller shaft to rear
    axle flange and tighten to48 Nm (35 lbf.ft).
    NOTE: Rotation of propeller shaft may be
    required during the above procedure.
    13.Fit nuts securing propeller shaft to park brake
    and tighten to48 Nm (35 lbf.ft).
    NOTE: Rotation of propeller shaft may be
    required during the above procedure.
    14.Remove stand(s) and lower vehicle. 
    						
    							PROPELLER SHAFTS
    1
    OVERHAUL PROPELLER SHAFT - FRONT
    Service repair no - 47.15.11
    Remove
    1.Remove front propeller shaft.See Repair.
    2.Thoroughly examine universal joints for signs of
    damage or wear.
    3.Clean universal joint bearing cups and circlips.
    CAUTION: To ensure correct assembly
    and reduce possibility of imbalance,
    before removing propeller shaft joint mark
    position of spider pin relative to journal yoke ears.
    4.Remove circlips.
    5.Note position and remove grease nipple.
    6.Tap yokes to eject bearing cups.
    7.Remove bearing cups.
    8.Remove spider.
    9.Clean yokes and bearing cup locations.Refit
    10.Remove bearing cups from new spider.
    11.Check all needle rollers are present and
    positioned in bearing cups.
    12.Enter new spider with seals into yokes of
    propeller shaft flange.
    13.Partially insert one bearing cup into flange yoke
    and enter spider trunnion into bearing cup.
    14.Insert opposite bearing cup into flange yoke.
    15.Press both cups into place.
    16.Press each cup into its respective yoke up to
    lower land of circlip groove. Damage may be
    caused to cups and seals if cups pass this point.
    17.Fit circlips and check no end float exists.
    18.Fit grease nipple and lubricate
    19.Repeat instructions for opposite end of propeller
    shaft as described in 1 to 9.
    20.Fit front propeller shaft.See Repair. 
    						
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