ecu LAND ROVER DEFENDER 1999 Workshop Manual

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.
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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).
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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.
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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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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.
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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 ,
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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.
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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.
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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.
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51REAR AXLE AND FINAL DRIVE
2
REPAIR Refit
15.Position axle and fit lower links. Tighten fixings
to176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair. Anti-roll bar
links.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten to correct torque:
Alloy wheels -130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)
24.Remove rear chassis support.
25.Bleed brake systemSee BRAKES, Repair.
brake system bleed.
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