LAND ROVER DEFENDER 1996 Workshop Manual

37MANUAL GEARBOX
4
REPAIR
37.Pull handbrake cable through heel board and tie
aside.
38.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39.Release speedometer cable from retaining clip
on transfer box.
40.Remove retaining nut and release battery earth
strap from transfer box.
41.Secure manufactured cradleLRT-99-007to a
suitable hydraulic hoist.
42.Raise hoist and secure to gearbox with 3 bolts in
location provided.
43.Lower hoist sufficiently to allow transfer lever to
clear transmission tunnel aperture.
44.Disconnect differential lock switch and reverse
light connectors.
45.Remove bolt and release earth leads from RH
side of transfer box.
46.Support engine under sump with a jack.
47.Remove 14 bell housing to engine fixings.
48.Withdraw transmission whilst ensuring all
connections to engine and chassis are released.
49.Lower hoist and remove gearbox assembly.

MANUAL GEARBOX
5
REPAIR Separating transfer gearbox from main gearbox
50.Remove transmission assembly from hoist
cradle and position safely on a bench.
51.Remove breather pipes. Discard pipe union
sealing washers.
52.Remove 'Nyloc' nut, and remove bolt, securing
lever to high/low shaft.
53.Collect spacer washer.
54.Remove 2 clips and remove differential lock
lever link.
55.Remove lower locknut from high/low operating
rod.
56.Place a sling round transfer box and attach to
hoist.
57.Remove nut and 4 bolts securing transfer
gearbox to extension housing.
58.Withdraw transfer gearbox.
Assembling transfer gearbox to main gearbox
59.Clean extension housing and transfer gearbox
mating faces.
60.Ensuring loose upper dowel is fitted, hoist
transfer gearbox into position.
61.Secure transfer box to extension housing.
Tighten fixings to
40 Nm (30 lbf/ft).
62.Connect high/low operating rod, fit and tighten
locknut.
63.Fit link to differential lock lever and secure with 2
clips
64.Align lever to high/low shaft, position washer, fit
bolt and new Nyloc nut. Tighten to
2 Nm (1.5
lbf/ft).
65.Position breather pipes, secure pipe unions
using new sealing washers. Tighten unions to
15
Nm (11 lbf/ft).
Fitting transfer gearbox and main gearbox
assembly
66.Position transmission assembly to hoist cradle.
67.Clean bell housing and engine mating faces.
Apply sealant to both mating faces.
68.Temporarily fit gear lever and select any gear in
main gearbox to facilitate entry of gearbox input
shaft. Engage low range.
69.Position and raise hoist, fit transmission to
engine whilst keeping harness and pipes clear to
prevent trapping.
70.Secure transmission to engine. Tighten fixings to
45 Nm (33 lbf/ft).
71.Secure earth leads to RH side of transfer box.
72.Connect reverse lamp switch connectors and
differential lock switch connectors.
73.Secure breather pipes to harness with clips.
74.Remove support from engine sump.
75.Position temporary support under transmission.
76.Secure LH and RH mounting brackets to
gearbox. Tighten fixings to
55 Nm (41 lbf/ft).
77.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.

37MANUAL GEARBOX
6
REPAIRREV: 05/99 78.Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
80.Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90
orSee MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81.Fit front pipe to exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe
.
82.Fit rear propeller shaft to transmission brake
drum. Tighten nuts to
47 Nm (33 lbf/ft).
83.Remove 3 bolts securing support cradle to
transmission and remove hoist.
84.Reconnect battery earth strap to transfer box
fixing.
85.Connect speedometer cable to transfer box and
secure with retaining clip.
86.Coat both sides of clutch slave clinder backing
plate with Hylomar P232M waterproof sealant.
87.Locate backing plate on slave cylinder.
88.Fit slave cylinder to bell housing, engaging
push-rod through centre of dust cover, and with
bleed screw uppermost. Tighten bolts to
25 Nm
(18 lbf/ft).
89.Fit front propeller shaft to transfer box. Tighten
nuts to
47 Nm (33 lbf/ft).
90.Refill main gearbox and transfer boxSee
MAINTENANCE , Under vehicle maintenance
.
91.Feed transmission brake cable through heel
board and ensure grommet is correctly located.
NOTE: Apply a soap solution to aid fitment
of cable.
92.Lower vehicle on ramp.
93.Fit ties to secure gearbox harness to
transmission breather pipes.
94.Fit breather pipe retaining clip to rear of engine.
95.Reconnect charge air hose at turbocharger.
96.Reconnect intake hose at induction manifold. If
EGR system is fitted, reconnect intake hose at
intercooler.
97.Reconnect radiator top hose at thermostat
housing.
98.Fit viscous fan unit
See COOLING SYSTEM,
Repair, Viscous coupling and fan
.
99.Reconnect battery.100.Refill cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
101.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
102.Locate insulation pad over gear levers and fit to
tunnel cover.
103.Fit gear lever with gaiter to lower lever spline
and secure with retaining nut.
104.Fit gear lever cover.
105.Fit gear lever and transfer box lever knobs.
106.Fit gearbox cover carpet.
107.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Under
vehicle maintenance
.

MANUAL GEARBOX
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Slave cylinder to bell housing 25....................................................................
Breather 15.....................................................................................................
Bell housing to cylinder block 40.....................................................................
High/low level to shaft 2.................................................................................
Transfer box to gearbox 45.............................................................................
NOTE: Torque values below apply to all screws and bolts used unless otherwise specified.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................

TRANSFER GEARBOX
1
DESCRIPTION AND OPERATION TRANSFER GEARBOX
Description
The transfer gearbox is a permanent 4 wheel drive,
two speed ratio reducing gearbox, incorporating high
and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
The transfer gearbox is mounted at the rear of the
main gearbox, the mainshaft of which extends into the
transfer casing. A transfer gear, supported on taper
roller bearings and splined to the gearbox mainshaft,
passes the drive to an intermediate gear cluster
supported on a single shaft and rotating on taper roller
bearings.The intermediate gears pass the drive to high and low
speed gears on the rear output shaft. The rear output
shaft passes through the speedo drive housing, which
also forms the mounting for the transmission brake. A
worm gear fitted to the rear output shaft drives a
pinion fitted in the speedo housing.
Integral with the output shafts is a differential
assembly which compensates for speed differences
between the front and rear prop shafts. To prevent all
the power being transmitted to the axle offering the
least resistance, a diff-lock is provided. The differential
lock should only be engaged during severe off-road
conditions and should be disengaged as soon as
conditions permit. Selection of differential lock
engages, through mechanical linkage, a dog clutch
with the front output shaft, this action locks the centre
differential and provides a fixed drive, giving equal
power to the front and rear output shafts.

TRANSFER GEARBOX
1
FAULT DIAGNOSIS TRANSFER GEARBOX - OIL SEAL LOCATIONS
1.Input seal.
2.Cover plate joints.
3.Front output seal.
4.Front and rear housing joint faces.5.Rear output seal.
6.Power take off cover plate joint.
7.Bearing plate joint.

41TRANSFER GEARBOX
2
FAULT DIAGNOSIS OIL LEAKS
Verify that oil leak is from transfer box and not main
gearbox before proceeding with checks.
Prior to road test
1.Check oil level in transfer box is correct.
2.Check tightness of level and drain plugs.
3.Check breather system for blockage. To validate
system pipe must be removed, inspected,
rectified as necessary and refitted.
4.Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
5.Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1.Drain oil and remove leaking output flange.
2.Inspect seal track on flange for surface damage.
If damaged renew component.
3.Remove and discard oil seal.
4.Inspect seal locating bore and remove any sharp
edges which may damage new oil seal.
5.Fit new seal.
6.Fit output flange and all other parts.
7.Add oil to correct level into gearbox
See
SECTION 10, Maintenance, Under vehicle
maintenance
.
Cover plate sealant leaking.
1.Drain oil and remove leaking cover plate.
2.Remove all traces of joint sealant from both joint
faces.
3.Degrease all components and apply a thin film of
Hylomar sealant, to both joint faces.
4.Apply thread sealant to bolts which come into
contact with gearbox oil.
5.Refit cover plate.
CAUTION: Care must be taken not to
overtighten fixings.Leak between main and transfer gearboxes.
1.Site vehicle onto a ramp .
2.Select neutral in transfer box and select 4th gear
in main gearbox.
3.Run engine at 2000 rpm with clutch/drive
engaged.
4.Observe joint between main and transfer boxes.
5.If oil leak is found establish if it is gear oil.
6.If so, leak is originating from transfer box.
7.Check two inner (main/transfer) bolts are oil
tight, as these holes are tapped into main
transfer case.
8.Remove transfer box to inspect mainshaft collar
seal track condition, and front face of transfer
case for porosity
See Repair, Transfer
gearbox
.
9.If these areas require servicing, transfer gearbox
input seal must also be renewed.
CAUTION: Avoid damaging new seal lip
and ensure seal is fitted flush with
machined face. Also ensure new seal is
not damaged when refitting transfer gearbox.
10.If red ATF type oil is seen leaking during
workshop test, investigate main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1.Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in transfer case and therefore
should be considered when looking for source of
leak.

TRANSFER GEARBOX
1
REPAIR TRANSFER GEARBOX
Service repair no - 41.20.25
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
adaptor plateLRT-99-010.
WARNING: Where use of a transmission
hoist is necessary, it is absolutely
essential to follow the manufacturers'
instructions to ensure safe and effective use of
the equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
or
See CHASSIS AND BODY, Repair, Rear undertray
.
1.Position vehicle on a ramp.
2.Select LOW range gear and leave vehicle in
neutral.
3.Disconnect battery.
4.Remove front, centre, seat cushion, or cubby
box
See CHASSIS AND BODY, Repair,
Cubby box
.
5.If fitted, disconnect multi-plug from EGR control
unit located on base of seat cushion or cubby
box.
6.Remove 4 screws securing centre access panel
to seat or cubby box base.
7.Release EGR and alarm system diagnostic
connector mounting bracket.
8.Lift up access panel, complete with diagnostic
connector harness, and place aside.
9.Remove breather pipe union from transfer
gearbox high/low cross-shaft housing.
10.Remove retaining clip and disconnect high/low
lever from operating rod.

41TRANSFER GEARBOX
2
REPAIR
11.Remove 3 trim studs and lift up handbrake
gaiter.
12.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
13.Release handbrake outer cable from heelboard.
14.Remove fan cowl
See COOLING SYSTEM,
Repair, Fan cowl
.
15.Raise vehicle on ramp.
16.Drain transfer box oil
See SECTION 10,
Maintenance, Under vehicle maintenance
.
17.Remove intermediate silencer.
See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90
orSee MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 110/130
.
18.Mark rear propeller shaft drive flange and
transmission brake drum for reassembly.
19.Remove 4 nuts, disconnect propeller shaft from
brake drum, and tie aside.
20.Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
21.Remove 4 nuts, disconnect propeller shaft from
transfer box, and tie aside.
22.Remove retaining clip at lower end of pivot arm
and disconnect differential lock control operating
rod.

TRANSFER GEARBOX
3
REPAIR 23.Position 4, 30 mm (1.25 in), spacers between
top of hoist and adaptor plate,LRT-99-010,at
securing points and secure adaptor plate to
hoist.
24.Remove 4 central bolts from transfer box bottom
cover, move hoist into position and secure
adaptor plate to transfer box.
25.Adjust hoist to take weight of transfer box.
26.Remove nut securing transfer box LH mounting
rubber to chassis crossmember.
27.Remove 4 nuts and bolts securing chassis
crossmember to chassis longitudinal.
28.Remove nut securing transfer box RH mounting
rubber to chassis crossmember.
29.Remove 4 nuts and bolts securing chassis
crossmember to chassis longitudinal.
30.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
31.Remove chassis crossmember.
32.Remove 4 bolts from both sides and remove LH
and RH mounting brackets from transfer box.
33.Disconnect electrical leads from differential lock
switch.
34.Move the small cranked lever, for high/low
selector, upward to allow access to adjacent nut
securing transfer box to main gearbox.
35.Position a jack to support main gearbox.
CAUTION: Use a block of wood or hard
rubber pad to protect gearbox.