maintenance LAND ROVER DEFENDER 1996 Owner's Guide

41TRANSFER GEARBOX
4
REPAIR
36.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer
gearbox.
37.Remove battery earth strap retaining nut, 1 nut
and 4 bolts, securing transfer box to main
gearbox extension case.
38.Remove retaining nut securing earth leads to RH
side of transfer box.
39.Fit three guide studs,LRT-41-009, through
transfer box bolt holes to support it during
removal.
40.Lower hoist and withdraw transfer box from main
gearbox.
41.Remove transfer box.Refit
42.Ensure joint faces of transfer box and main
gearbox are clean and guide studs,LRT-41-009,
are fitted to extension case.
43.Lubricate oil seal in joint face of transfer box.
44.Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
45.Remove guide studs, fit battery earth strap, and
secure transfer box to main gearbox extension
case. Tighten fixings to
45 Nm (33 lbf/ft).
46.Fit electrical leads to differential lock switch.
47.Raise hoist and remove wooden block
supporting main gearbox.
48.Secure LH and RH mounting brackets to
gearbox and tighten fixings to
55 Nm (41 lbf/ft).
49.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
50.Position chassis crossmember and locate over
fixing studs of LH and RH gearbox mounting
rubbers .
51.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.
52.Remove body jack.
53.Fit retaining nut to LH and RH mounting rubbers.
Tighten to
21 Nm (15 lbf/ft).
54.Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
55.Lower hoist and move aside.
56.Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to
25 Nm (18 lbf/ft).
57.Fit earth leads to RH side of transfer box.
58.Connect differential lock control operating rod to
pivot arm.
59.Fit speedometer cable to transfer box.
60.Fit front and rear propeller shafts to transfer box.
Tighten nuts to
47 Nm (33 lbf/ft).
61.Fit intermediate silencer.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
silencer - 90; Refit
orSee MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 110/130; Refit
.
62.Refill transfer box with recommended oil
See
SECTION 10, Maintenance, Under vehicle
maintenance

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
.

PROPELLER SHAFTS
1
DESCRIPTION AND OPERATION PROPELLER SHAFT
Description
The front and rear propeller shafts have non-constant
velocity type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and protected by a rubber gaiter. A
grease nipple is also fitted for servicing requirements.
The front shaft which is shorter than the rear is
'phased', with the joints at each end, A and B
mis-aligned as shown.
The phasing is necessary on the front shaft only to
allow for greater variation in angular changes.
Propeller shaft
1.Flanged yoke
2.Grease nipple
3.Journal spider
4.Needle roller bearing
5.Circlip
6.Splined shaft
7.Rubber gaiter (dust cap)
8.Splined shaft

FRONT AXLE AND FINAL DRIVE
5
OVERHAUL 38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with 7
bolts. Tighten to
73 Nm (54 lbf/ft).
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts.
78 Nm (58 lbf/ft),bend over lock tabs.
46.Tighten top swivel pin bolts to
78 Nm (58 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to
78 Nm (58 lbf/ft),and bend over lock
tabs.
49.Apply recommended grease between lips of
swivel oil seal.50.Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to
11 Nm (8
lbf/ft).
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to
40 Nm (30 lbf/ft).
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm (8 lbf/ft).
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.
Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 O'clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to
65 Nm (48 lbf/ft).
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit complete front hub assembly
See Repair,
Front hub assembly
.
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil
See SECTION 10, Maintenance, Under
vehicle maintenance
.
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67.Set steering lock stop bolts
See STEERING,
Adjustment, Steering lock stops
.

57STEERING
6
REPAIR POWER STEERING SYSTEM - BLEED
Service repair no - 57.15.02
1.Check that fluid level is at maximum level
See
MAINTENANCE , Under bonnet maintenance.
2.Run engine to normal operating temperature.
3.Recheck reservoir fluid level, top up if necessary
NOTE: During operations 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
4.With engine at idle speed, slacken bleed screw.
When fluid seeps past bleed screw retighten
screw.
5.Check fluid level.
6.Clean away fluid around bleed screw.
7.Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
8.Carry out road test.POWER STEERING FLUID RESERVOIR
Service repair no - 57.15.08
Remove
1.Position drain tin beneath reservoir.
2.Slacken mounting bracket clamp bolt and raise
reservoir to gain access to feed and return hose
retaining clips.
3.Slacken clips, disconnect hoses from reservoir,
allow fluid to drain.
4.Remove reservoir.
CAUTION: Plug connections to prevent
ingress of dirt.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact
paintwork, if spilled, remove fluid and
clean area with warm water.
Refit
5.Position reservoir, connect feed and return
hoses and tighten clips to
3 Nm (2 lbf/ft).
6.Fit reservoir in clamp, tighten clamp bolt.
7.Fill reservoir between upper mark and end of
dipstick with power steering fluid
See
MAINTENANCE , Under bonnet maintenance
.
8.Bleed power steering system
See Power
steering system - bleed
.

AIR CONDITIONING
7
ADJUSTMENT 11.All precautions must be taken to prevent
damage to fittings and connections. Slight
damage could cause a leak with the high
pressures used in the system.
12.Always use two wrenches of the correct size,
one on each fitting when releasing and
tightening refrigeration unions.
13.Joints and 'O' rings should be coated with
refrigeration oil to aid correct seating. Fittings
which are not lubricated with refrigerant oil are
almost certain to leak.
14.All lines must be free of kinks. The efficiency of
the system is reduced by a single kink or
restriction.
15.Flexible hoses should not be bent to a radius
less than 90mm radius.
16.Flexible hoses should not be within 100mm of
the exhaust manifold.
17.Completed assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of lines and panels transmits noise
and must be eliminated.PERIODIC MAINTENANCE
Routine servicing, apart from visual checks, is not
necessary. The visual inspections are as follows:
Condenser
With a water hose or air line, clean the fins of the
condenser to remove flies, leaves, etc. Check the pipe
connections for signs of oil leakage.
Compressor
Check pipe connections for signs of oil leakage.
Check flexible hoses for swelling. Examine the
compressor belt for tightness and condition.
Sight glass
Examine the sight glass for bubbles with the system
operating. Check connections for leakage.
Evaporator
Examine the refrigeration connections at the unit.

ELECTRICAL
1
DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of electrical
connections at all times. Any incorrect connections
made when reconnecting cables may cause
irreparable damage to semi-conductor devices used in
generator and regulator. Incorrect polarity would also
seriously damage any transistorized equipment such
as a radio.
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect battery negative lead first. If
positive lead is disconnected with negative lead in
place, accidental contact of wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery positive lead should be
connected first.
GENERATOR
The generator is a three phase, field sensed unit. The
rotor and stator windings produce three phase
alternating current, AC, which is rectified to direct
current, DC. The electronic voltage regulator unit
controls generator output voltage by high frequency
switching of the rotor field circuit. Use only correct
replacement drive belt. Occasionally check that
engine and generator pulleys are accurately aligned.
It is essential that good electrical connections are
maintained at all times. Of particular importance are
those in the charging circuit (including those at
battery) which should be occasionally inspected to
see that they are clean and tight. In this way any
significant increase in circuit resistance can be
prevented.Do not disconnect battery cables while engine is
running or damage to semi-conductor devices may
occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while engine is running.
The electronic voltage regulator employs micro-circuit
techniques resulting in improved performance under
difficult service conditions. The whole assembly is
encapsulated in silicone rubber and housed in an
aluminium heat sink, ensuring complete protection
against adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give required regulating voltage range of 14.2±0.2
volts, and no adjustment is necessary. The only
maintenance needed is occasional check on terminal
connections and wiping with a clean dry cloth.
The generator system provides for direct connection
of a charge (ignition) indicator warning lamp, and
eliminates the need for a field switching relay or
warning light control unit. In the event of bulb failure,
an 'exciter' voltage is supplied through a resistor,
wired in parallel to the bulbs, ensuring that generator
output is maintained. The lamp should be checked
regularly.
When using rapid charge equipment to re-charge
battery, the battery must be disconnected from the
vehicle.

ELECTRICAL
1
FAULT DIAGNOSIS GENERAL INFORMATION
Detailed information of electrical systems, component
locations and circuit diagrams are covered in the
Defender Electrical Troubleshooting Manual.
This section covers checks of the charging system.
GENERATOR TESTING
Service repair no - 86.10.01
Charging system check
1.Check battery is in good condition, with an open
circuit voltage of at least 12.6 V. Recharge or
substitute battery to carry out test.
2.Check drive belt condition
See SECTION 10,
Maintenance, Under bonnet maintenance.
3.Check battery connections are clean and tight.
4.Check generator connections are clean and
tight.
5.Ensure there is no drain on battery from, for
example, interior or exteriorlamps.
Generator test
Following instructions refer to use of suitable test
equipment using a carbon pile rheostat.
6.Connect test equipment referring to
manufacturer's instructions.
7.Start engine and run at 3000 rev/min without
accessory load.
8.Rotate carbon pile load control to achieve
greatest output (amps) without allowing voltage
to fall below 12.0 V. A reading in amps, of
generator output should be obtained.
9.Run engine at 3000 rev/min, switch selector to
regulator test, read voltmeter. A reading of 13.6
to 14.4 V should be obtained.
10.Switch selector to diode/stator test, switch on
headlamps to load generator. Raise engine
speed to 3000 rev/min, read voltmeter, needle
must be within 'OK' range.TESTING IN POSITION
Charging circuit resistance test.
1.Connect a low range voltmeter between
generator terminal marked B+ and positive
terminal of battery.
2.Switch on headlamps, start engine. Run engine
at approximately 3000 rev/min. Note voltmeter
reading.
3.Transfer voltmeter connections to frame of
generator and negative terminal of battery, and
again note voltmeter reading.
4.If reading exceeds 0.5 volt on positive side or
0.25 volt on negative side, there is a high
resistance in charging circuit which must be
traced and remedied.

86ELECTRICAL
2
REPAIR BATTERY
Service repair no - 86.15.01
NOTE: If the vehicle is fitted with a battery
backed-up alarm sounder, disconnecting
the vehicle battery will cause the alarm to
sound unless the following procedure is followed:
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Slacken battery negative lead clamp bolt.
4.Turn starter switch 'on'.
5.Turn starter switch 'off' and remove key.
6.Disconnect battery WITHIN 15 SECONDS.
If alarm is accidentally activated, ensure sounder is
connected and silence by turning the starter switch to
position 'II'.Remove
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect negative lead first. If positive
lead is disconnected with negative lead in place,
accidental contact of a wrench to any grounded
metal part could cause a severe spark, possibly
resulting in personal injury. Upon installation of
battery always connect positive lead first.
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Disconnect both battery leads, negative first.
4.Slacken securing nuts and move battery clamp,
with 'J' bolts aside.
5.Remove battery.
NOTE: Coat battery clamps and terminals
with petroleum jelly before refitting.
Refit
6.Position battery and secure with clamp. Ensure
'J' bolts are hooked correctly under retaining
brackets on base of battery box.
7.Reconnect battery leads, positive lead first.
8.Fit battery access cover.
9.Fit seat cushion.