wheel LAND ROVER DEFENDER 1996 Owner's Guide

19FUEL SYSTEM
2
REPAIR
13.Remove banjo bolts securing spill return, main
fuel and boost signal pipes, refit banjo bolts after
disconnecting pipes.
14.Remove 2 bolts securing rear of pump to
mounting bracket.
15.Remove 3 pump securing nuts at flange and
withdraw pump and gasket.
16.Fit suitable caps to pipe connections to prevent
ingress of dirt.
Refit
17.Clean mating faces of pump and front cover and
fit new gasket into position over pump mounting
studs.
18.Remove pump blanking plugs.
19.Slacken the 3 bolts, securing injection pump
mounting bracket to cylinder block, sufficiently
enough to allow bracket to move.
20.Fit pump to cover and secure with 3 nuts.
Tighten to
25 Nm (18 lbf/ft).
21.Loosely attach pump to mounting bracket with
nuts and bolts, then tighten bolts securing
bracket to cylinder block and bolts securing
pump to bracket, finger tight only.
22.To ensure correct fitting and alignment of
injection pump, first tighten the 2 bolts securing
pump to mounting bracket to
25 Nm (18 lbf/ft).
Then tighten the 3 bolts securing mounting
bracket to cylinder block, also to
25 Nm (18
lbf/ft).
23.Connect spill return and main fuel pipes and
secure with banjo bolts. Tighten to
25 Nm (18
lbf/ft).
24.Connect boost signal pipe and secure with banjo
bolt. Tighten to
10 Nm (7 lbf/ft).
25.Connect fuel cut-off solenoid lead and throttle
position sensor multi-plug, if fitted.
26.Connect throttle cable and where applicable,
hand throttle cable.
27.Remove pump gear retaining toolLRT-12-045.
28.Carefully turn the pump hub nut in a clockwise
direction, sufficiently enough to enable timing
tool pin to be inserted into injection pump.
29.Fit gear retaining plate and secure with 3 bolts.
Tighten to
25 Nm (18 lbf/ft).
30.Remove timing pin.
31.Ensure flywheel timing pin is disengaged from
slot in flywheel.
32.Turn crankshaft two complete revolutions, check
timing pin fromRT-12-045can be fully and
easily inserted into the pump. At the same time
check flywheel timing pinLRT-12-044can also
be inserted in the flywheel slot.
33.If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
a.Ensure flywheel timing pin is disengaged from
slot in flywheel.
b.Slacken the 3 pump gear retaining bolts.
c.Turn the pump hub nut in a clockwise
direction, sufficiently to enable timing tool pin to
be easily inserted into the injection pump.
d.Keeping the tension on the hub nut, check
that flywheel timing pin locates with slot in
flywheel.
e.Tighten the 3 pump gear retaining bolts to
25
Nm (18 lbf/ft).
f.Remove timing pins from pump and flywheel
housing.
34.Using a suitable anti-seize compound, fit the
blanking plug to flywheel housing. Tighten to
12
Nm (9 lbf/ft).
35.Fit access plate with gasket to front cover plate.
Tighten bolts to
25 Nm (18 lbf/ft).
36.Refit injector pipes.
37.Reconnect battery.

CLUTCH
1
DESCRIPTION AND OPERATION DESCRIPTION
The clutch unit comprises a single dry plate friction
disc and diaphragm spring clutch unit, secured to the
engine flywheel.OPERATION
The unit is operated hydraulically by the clutch master
cylinder (12) and a slave cylinder (13) attached to the
transmission bell housing.
Clutch components
1.Crankshaft and flywheel
2.Friction plate
3.Clutch cover
4.Diaphragm spring
5.Pressure plate
6.Fulcrum posts (9) for diaphragm spring
7.Bearing rings (2) for diaphragm spring
8.Retraction links and bolts (3) for pressure plate
9.Release bearing10.Release lever
11.Release lever pivot post
12.Master cylinder
13.Slave cylinder
14.Master cylinder pedal pushrod
15.Primary shaft and taper bearing (in gearbox)
16.Gearbox front cover
17.Primary shaft flywheel bush
18.Pedal pivot and return spring

33CLUTCH
2
DESCRIPTION AND OPERATION
When the clutch pedal is depressed, hydraulic fluid
transmits the movement via the slave cylinder, release
lever (10), bearing (9), to the inner fingers of the
diaphragm spring (4).
The diaphragm spring (4) pivots on the bearing rings
(7) and fulcrum posts (6) causing the pressure plate
(5) to release the clamping force on the friction plate
and linings (2).As the the clamping force is removed from the friction
plate (2), the plate slides on the splines of the primary
shaft (15) and takes up a neutral position between the
flywheel (1) and the pressure plate (5), thus
disconnecting the drive between the engine and the
gearbox.

CLUTCH
1
FAULT DIAGNOSIS CLUTCH ASSEMBLY CONDITIONS
For the clutch to operate correctly it is important the
following conditions are satisfied:-
·The primary shaft (15) must be free in the
crankshaft spigot bush (17).
·The friction plate (2) must be able to slide easily on
the splines on the primary shaft (15), to a position
where it does not contact either the flywheel or the
pressure plate.
·The friction plate must not be distorted or the
linings contaminated with oil, which may cause it to
stick or continue to run in contact with the flywheel
or pressure plate.
A number of faults can develop in the operation of the
clutch for a variety of reasons and most faults are due
to normal wear at high mileage. Problems can also
occur if the unit has been renewed by an unskilled
operator.
Recognising and diagnosing a particular clutch fault is
therefore of paramount importance in ensuring that
the problem is rectified at the first attempt.
Problems which develop in the clutch are as follows:-
·Clutch spin/drag
·Clutch slip
·Clutch judder/fierceCLUTCH SPIN - DRAG
Symptoms
Clutch spin is that, with engine running and clutch
pedal depressed, the gears cannot be immediately
engaged without making a grinding noise. This
indicates the clutch is not making a clean break.
However, if the clutch pedal is held depressed for
several seconds the friction plate will eventually break
free from the engine and the gear will engage silently.
Clutch spin as it becomes more severe develops into
clutch drag, making the silent engagement of a gear
impossible, regardless of how long the pedal is held
depressed.
CLUTCH SLIP
Symptoms
Clutch slip is most evident climbing a hill or when the
vehicle is moving off from stationary with a heavy
load. As the clutch is released, slip occurs between
the engine and the transmission, allowing the engine
speed to increase without a corresponding increase in
vehicle speed.
Clutch slip can develop to the stage where no power
is transmitted through the clutch as the pedal is
released.
CLUTCH JUDDER - FIERCE
Symptoms
Clutch judder or fierce engagement, like slip, is most
likely to occur when the vehicle is moving off from
stationary. As the clutch pedal is released the vehicle
will move rapidly or in a series of jerks, which cannot
be controlled even by careful operation of the clutch
by the driver.
It should be noted that a vehicle may display all the
symptoms or any combination of the symptoms
described, depending on the driving conditions vehicle
load and operating temperatures.

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01
Clutch pressure plate
Renew pressure plate if diaphragm spring fingers are
worn or if pressure plate shows signs of wear, cracks
or burning.
Clutch driven plate
Renew driven plate if centre hub splines are worn or if
lining is contaminated, burned or unevenly worn.
Remove
1.Remove gearbox
See MANUAL GEARBOX,
Repair, R380 Gearbox
.
2.Mark position of clutch pressure plate to flywheel
for reassembly.
3.Remove pressure plate securing bolts, working
evenly and diagonally.
4.Remove clutch assembly.
5.Withdraw clutch driven plate.
Refit
NOTE: To prevent driven plate sticking,
lubricate splines using Rocol MV 3 or
Rocol MTS 1000 grease.
6.Using centralising toolLRT-12-040to support
clutch driven plate locate pressure plate on
flywheel dowels. If fitting original pressure plate,
align assembly marks.
7.Secure pressure plate cover fixings evenly,
working in a diagonal sequence. Tighten to
34Nm (25 lbf/ft).
8.Fit gearbox to engineSee MANUAL
GEARBOX, Repair, R380 Gearbox
.BLEED HYDRAULIC SYSTEM
Service repair no - 33.15.01
Procedure
NOTE: During bleed procedure, keep fluid
reservoir topped up to avoid introducing
air to system. For hydraulic fluid
recommendations
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information, Recommended
lubricants and fluids
.
1.Attach suitable tubing to slave cylinder bleed
screw.
2.Place free end of tube in a glass jar containing
clutch fluid.
3.Loosen bleed screw.
4.Pump clutch pedal, pausing at end of each
stroke, until fluid from tubing is free of air.
NOTE: Keep free end of tube below
surface of fluid.
5.Hold clutch pedal down, tighten bleed screw.
6.Top up fluid reservoir.

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.

PROPELLER SHAFTS
1
FAULT DIAGNOSIS VIBRATION HARSHNESS
Check that the propeller shaft universal joints and
sliding splines are not siezed or worn and that the
shafts are correctly aligned.
NOTE: In the event that both shafts are
satisfactory, but the vibration/harshness is
still present, the transfer box operation
and balance of the road wheels should be
checked.
For transfer box operation
See TRANSFER
GEARBOX, Fault diagnosis, Transfer Gearbox -
Oil seal locations
.
For balance of road wheels
See WHEELS AND
TYRES, Repair, Wheel Balancing.

REAR AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel rear axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease.The hub bearings are fitted with inner and outer seals.
The outer seals prevent the differential oil mixing with
the hub grease and the inner seals prevent dirt
ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
Rear axle hub - 90
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle6.Wheel bearings
7.Inner hub seal
8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc

51REAR AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION
Rear axle hub - 110/130
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle
6.Wheel bearings
7.Inner hub seal8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
11.Drive flange
12.Drive shaft circlip
13.Dust cap

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect shock absorbers.
6.Disconnect flexible brake hose at RH chassis
side member and breather hose at banjo
connection on axle casing.
7.Disconnect lower links at axle.8.Mark differential and propeller shaft flanges with
identification marks for assembly.
9.Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.If applicable, remove anti-roll bar links at axle
See REAR SUSPENSION, Repair, anti-roll
bar
.
14.Remove axle assembly.