brake LAND ROVER DEFENDER 1996 Owner's Guide

FUEL SYSTEM
17
REPAIR EGR VALVE
Service repair no - 17.45.01
Remove
1.Disconnect multi-plug from EGR valve.
2.Disconnect vacuum pipe from EGR valve.
3.Remove 2 Allen screws securing EGR valve to
exhaust manifold.
4.Remove 2 bolts securing air inlet delivery tube to
EGR valve.
5.Remove EGR valve and discard gaskets.
Refit
6.Clean mating faces of EGR valve and exhaust
manifold.
7.Position new gaskets and fit EGR valve to
delivery tube and exhaust manifold. Tighten
bolts to
25 Nm (18 lbf/ft).
8.Fit vacuum pipe and multi-plug to EGR valve.EGR VALVE MODULATOR
Service repair no - 17.45.04
Remove
1.Disconnect multi-plug from modulator.
2.Disconnect spill pipe (green), modulator to air
cleaner hose.
3.Disconnect vacuum pipe (blue), modulator to
EGR valve.
4.Disconnect vacuum pipe (white), modulator to
brake servo pipe.
5.Unscrew 2 nuts securing modulator to flexible
mountings.
6.Remove modulator.
Refit
7.Fit modulator to flexible mountings and tighten
nuts to
8 Nm (6 lbf/ft).
8.Fit modulator pipes, ensuring they are connected
to correct ports.
9.Connect modulator multi-plug.

37MANUAL GEARBOX
2
ADJUSTMENT FIFTH GEAR STOP SCREW - ADJUST
Service repair no - 37.16.67
1.Remove gear lever and transfer box lever knobs.
2.Remove gear lever cover.
3.Remove nut and washer securing gear lever.
4.Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5.Remove insulation pad from tunnel aperture.
6.Remove tunnel carpet.
7.Remove retaining screws and release fuse box
cover.
8.Remove 2 screws and release fuse box from
bulkhead to assist next operation.
9.Remove 16 screws securing tunnel cover to
vehicle body.
10.Manouvre tunnel cover to clear handbrake lever
and remove from vehicle.
11.Fit gear lever and knob and select reverse gear.

37MANUAL GEARBOX
2
REPAIR
10.Remove 3 trim studs and lift up handbrake
gaiter.
11.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
12.Drain cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system
.
13.Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan
.
14.Slacken retaining clip and disconnect radiator
top hose at thermostat housing.
15.Slacken retaining clip and disconnect intake
hose at induction manifold. If EGR system is
fitted, slacken 2 retaining clips and disconnect
intake hose at intercooler.
16.Slacken retaining clip and disconnect hose at
turbocharger.
17.Remove bolt securing transmission breather
pipe clip to rear of engine.
18.Release breather pipes.
19.Release ties securing gearbox harness to
breather pipes.
20.Raise vehicle on ramp.
21.Position a suitable container under transmission
and drain main gearbox and transfer box
See
MAINTENANCE , Under vehicle maintenance
.
22.Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
23.Remove 4 nuts and disconnect propeller shaft
from transfer box.

MANUAL GEARBOX
3
REPAIR
24.Remove 2 bolts, withdraw clutch slave cylinder
and backing plate from bell housing, and tie
aside.
25.Mark rear propeller shaft drive flange and
transmission brake drum for reassembly.
26.Remove 4 nuts, disconnect propeller shaft from
brake drum, and tie aside.
27.Remove front pipe from exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe
.
28.Remove intermediate silencer.
See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90
orSee MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 110/130
29.Temporarily support transmission.
30.Remove nut securing gearbox LH mounting
rubber to chassis crossmember.
31.Remove 4 nuts and bolts securing crossmember
to chassis longitudinals.
32.Remove nut securing transfer box mounting
rubber to RH side of crossmember.
33.Remove 4 nuts and bolts securing crossmember
to chassis longitudinals.
34.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
35.Remove chasss crossmember.
36.Remove 4 bolts from both sides and remove LH
and RH mounting brackets.

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.

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
.

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.

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
5
REPAIR REV: 05/9963.Feed transmission brake cable through heel
board. Ensure cable grommet is correctly
located.
NOTE: Apply a soap solution to aid fitment
of cable.
64.Lower vehicle ramp.
65.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
66.Connect high/low lever to operating rod.
67.Fit breather pipe banjo union to high/low
cross-shaft housing.
68.Fit centre access panel to seat base. If fitted,
secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.
69.If fitted, reconnect multi-plug to EGR control unit
on base of centre seat cushion or cubby box.
70.Fit seat cushion or cubby box
See CHASSIS
AND BODY, Repair, Cubby box
.
71.Reconnect battery.
72.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Handbrake
cable
.

TRANSFER 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
Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................