service LAND ROVER DEFENDER 1999 Workshop Manual

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 ,
ProCarManuals.com

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.
ProCarManuals.com

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.
ProCarManuals.com

PROPELLER SHAFTS
1
OVERHAUL PROPELLER SHAFT - FRONT
Service repair no - 47.15.11
Remove
1.Remove front propeller shaft.See Repair.
2.Thoroughly examine universal joints for signs of
damage or wear.
3.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance,
before removing propeller shaft joint mark
position of spider pin relative to journal yoke ears.
4.Remove circlips.
5.Note position and remove grease nipple.
6.Tap yokes to eject bearing cups.
7.Remove bearing cups.
8.Remove spider.
9.Clean yokes and bearing cup locations.Refit
10.Remove bearing cups from new spider.
11.Check all needle rollers are present and
positioned in bearing cups.
12.Enter new spider with seals into yokes of
propeller shaft flange.
13.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
14.Insert opposite bearing cup into flange yoke.
15.Press both cups into place.
16.Press each cup into its respective yoke up to
lower land of circlip groove. Damage may be
caused to cups and seals if cups pass this point.
17.Fit circlips and check no end float exists.
18.Fit grease nipple and lubricate
19.Repeat instructions for opposite end of propeller
shaft as described in 1 to 9.
20.Fit front propeller shaft.See Repair.
ProCarManuals.com

47PROPELLER SHAFTS
2
OVERHAUL PROPELLOR SHAFT - REAR
Service repair no - 47.15.12
Remove
1.Remove rear propeller shaft.See Repair.
2.Thoroughly examine universal joint for signs of
damage or wear.
3.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance,
before removing propeller shaft joint mark
position of spider pin relative to journal yoke ears.
4.Remove circlips.
5.Remove grease nipple.
6.Tap yokes to eject bearing cups.
7.Remove bearing cups.
8.Remove spider.
9.Clean yokes and bearing cup locations.Refit
10.Remove bearing cups from new spider.
11.Check all needle rollers are present and
positioned in bearing cups.
12.Enter new spider with seals into yokes of
propeller shaft flange.
13.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
14.Insert opposite bearing cup into flange yoke.
15.Press both cups into place.
16.Press each cup into its respective yoke up to
lower land of circlip groove. Damage may be
caused to cups and seals if cups pass this point.
17.Fit circlips and check no end float exists.
18.Fit grease nipple and lubricate.
19.Repeat instructions for opposite end of propeller
shaft as described in 3 to 9.
20.Fit rear propeller shaft.See Repair.
ProCarManuals.com

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.
ProCarManuals.com

REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY - 90
Service repair no - 64.15.01
Remove
1.Place rear axle onto axle stands and remove
road wheel.
2.Release brake hose clips and remove brake
caliper bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.
3.Remove 5 bolts and withdraw axle shaft.
4.Remove joint washer.
5.Bend back lock washer tabs.
6.Remove locknut and lock washer.
7.Remove hub adjusting nut.
8.Remove spacing washer.
9.Remove hub and brake disc assembly complete
with bearings.
Rear hub components - 90
1.Axle shaft.
2.Axle shaft joint washer.
3.Axle shaft retaining bolt.
4.Lock nut.
5.Lock washer.
6.Hub adjusting nut.
7.Spacing washer.8.Outer bearing.
9.Hub.
10.Inner bearing.
11.Grease seal.
12.Brake disc.
13.Disc retaining bolt.
ProCarManuals.com

REAR AXLE AND FINAL DRIVE
5
REPAIR DIFFERENTIAL ASSEMBLY - 90
Service repair no - 51.15.01
Remove
1.Using suitable container, drain axle oil.
2.Mark differential and propeller shaft flanges to
facilitate reassembly.
3.Remove 4 bolts and disconnect propeller shaft
from differential. Tie aside.
4.Remove 5 hub drive member bolts and withdraw
axle half shafts sufficiently to disengage from
differential unit.
5.Remove 10 nuts securing differential to axle
case.
6.Withdraw differential unit.
NOTE: The differential unit can only be
serviced as a complete assembly with
matching drive pinion. For advice ring
Land Rover Service Department.Refit
7.Ensure mating faces are clean and apply a bead
of RTV sealant to axle case.
8.Support differential unit and position on axle
casing.
9.Secure with self locking nuts and tighten to40
Nm (30lbf/ft).
10.Align marks on flanges and secure propeller
shaft to differential. Tighten bolts to48 Nm (35
lbf/ft).
11.Refit half shafts, using new drive member
gaskets. Tighten bolts to65 Nm (48 lbf/ft).
12.Refill axle oil with approved lubricantSee
LUBRICANTS, FLUIDS AND CAPACITIES,
Information. Recommended lubricants and
fluids.
ProCarManuals.com

REAR AXLE AND FINAL DRIVE
1
OVERHAUL DIFFERENTIAL ASSEMBLY - 110/130
Service repair no - 51.15.07
Overhaul
1.Drain off differential lubricating oil, and refit plug.
2.Remove rear axle assembly from vehicleSee
Repair. Rear axle
3.Remove hub driving member fixings.
4.Withdraw driving member and axle shaft
sufficiently to disengage differential.
5.Repeat instruction 4 for other axle shaft.
6.Remove fixings and support strip at differential
cover and withdraw cover and joint washer.
7.Note relationship marking on bearing caps and
axle casing to ensure correct refitting.
8.Remove fixings and withdraw differential bearing
caps.
9.Clean out and examine spreader tool peg holes
provided in gear casing face; ensure that holes
are free from dirt and burrs and damage.
10.Ensure that turnbuckle adjuster is free to turn.
Using axle compressor LRT-51-503
11.Place tool on to differential casing, as illustrated,
with weld seam uppermost. Ensure that plates
rest squarely on differential machined surface
and end bars butt against edges of casing.
12.Tighten adjusting nuts by hand only, until all
slack is taken up.
13.Continue to tighten both nuts alternately with a
spanner, one flat at a time, to a maximum of
three flats.
14.Carefully lever-out differential assembly.
ProCarManuals.com

51REAR AXLE AND FINAL DRIVE
10
OVERHAUL REAR HUB ASSEMBLY - 90
Service repair no - 64.15.13.
1.Remove rear hubSee Repair. Rear hub
assembly.
2.Remove outer bearing.
3.Mark, for reassembly, position of hub to brake
disc.4.Remove 5 bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
5.Remove grease seal and inner bearing from
hub.
6.Remove inner and outer bearing tracks.
REAR HUB COMPONENTS - 90
1.Axle shaft.
2.Axle shaft joint washer.
3.Axle shaft retaining bolt.
4.Lock nut.
5.Lock washer.
6.Hub adjusting nut.
7.Spacing washer.8.Outer bearing.
9.Hub.
10.Inner bearing.
11.Grease seal.
12.Brake disc.
13.Disc retaining bolt.
ProCarManuals.com