oil LAND ROVER DEFENDER 1999 Workshop Manual

33CLUTCH
8
DESCRIPTION AND OPERATION The dual mass flywheel is bolted on the rear of the crankshaft with eight bolts. A dowel on the crankshaft flange
ensures that the flywheel is correctly located. A ring gear is fitted on the outer diameter of the flywheel. The ring
gear is not serviceable. Thirty blind holes are drilled in the outer diameter of the flywheel adjacent to the ring gear.
The holes are positioned at 10°intervals with four 20°spaces. The holes are used by the crankshaft position
sensor for engine management.
The dual mass flywheel is used to insulate the gearbox from torsional and transient vibrations produced by the
engine. The flywheel comprises primary and secondary flywheels with the drive between the two transferred by a
torsional damper which comprises four coil springs. The springs are located in the inside diameter of the primary
flywheel. Two of the springs are of smaller diameter and fit inside the larger diameter springs.
The primary flywheel locates the ring gear and is attached to the crankshaft flange with eight bolts. The two pairs
of coil springs are located in a recess in the flywheel between two riveted retainers. A roller bearing is pressed
onto the central boss of the primary flywheel and retained with a riveted plate. The bearing provides the mounting
for the secondary flywheel.
The secondary flywheel comprises two parts; an outer flywheel which provides the friction surface for the clutch
drive plate and an inner drive plate which transfers the drive from the primary flywheel, via the coil springs, to the
outer flywheel. The two components of the secondary flywheel are secured to each other with rivets. The inner
drive plate is located between the two pairs of coil springs and can rotate on the ball bearing in either direction
against the combined compression force of the four coil springs. Under high torque loading conditions the
secondary flywheel can rotate in either direction up to 70°in relation to the primary flywheel.
The operating face of the secondary flywheel is machined to provide a smooth surface for the drive plate to
engage on. Three dowels and six studs and nuts provide for the location and attachment of the pressure plate.
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37 - MANUAL GEARBOX
CONTENTS
Page
ADJUSTMENT
SPRINGS - GEAR LEVER BIAS 1..........................................................................
GEARBOX OIL - DRAIN AND REFILL 2.................................................................
REPAIR
COVER - FRONT - RESEAL AND FIT NEW INPUT SHAFT OIL SEAL 1..............
LEVER - GEAR CHANGE 3....................................................................................
MECHANISM AND HOUSING - GEAR SELECTOR 4...........................................
MECHANISM AND HOUSING - GEAR SELECTOR - RESEAL 6..........................
GEARBOX 7...........................................................................................................
SWITCH - REVERSE LIGHT 12.............................................................................
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37MANUAL GEARBOX
2
ADJUSTMENT GEARBOX OIL - DRAIN AND REFILL
Service repair no - 37.24.01
Drain
1.The oil should be drained when the gearbox is
warm and the vehicle is standing on a level
surface.
WARNING: Observe due care when
draining gearbox as oil can be very hot.
2.Raise vehicle on ramp.
3.Position container to collect oil.
4.Clean area around filler/level plug.
5.Remove filler/level plug.
NOTE: Later gearboxes: Use No. 55 Torx
bit to remove filler/level plug.
6.Remove gearbox drain plug and discard sealing
washer.Refill
1.Clean gearbox drain plug and fit new sealing
washer.
2.Fit gearbox drain plug and tighten to50 Nm (36
lbf.ft).
3.Fill gearbox with correct grade of oil.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
4.Apply Loctite 290 to the filler/level plug and
tighten to30 Nm (22 lbf.ft).
5.Remove fluid container.
6.Lower vehicle on ramp.
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MANUAL GEARBOX
1
REPAIR COVER - FRONT - RESEAL AND FIT NEW INPUT
SHAFT OIL SEAL
Service repair no - 37.12.33.01
Remove
1.Remove gearbox.See this Section.
2.Remove retaining peg and remove release
bearing.
3.Remove bolt securing clutch release fork,
remove retaining clip and remove clutch release
fork.
4.Remove 2 bolts securing release bearing sleeve,
remove bearing sleeve.
5.Remove 6 bolts securing clutch housing, remove
housing.
6.Remove and discard 6 bolts securing front
cover, remove cover.
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37MANUAL GEARBOX
2
REPAIR
7.Using a soft metal drift, carefully remove input
shaft front bearing track from front cover.
CAUTION: Take care not to damage
bearing track, if track is damaged, it will be
necessary to fit a new input shaft front
bearing.
8.Remove input shaft oil seal from front cover;
discard oil seal.
Refit
9.Using a suitable solvent clean seal recess, front
cover and gearbox mating faces; clean threads
of bolts and bolt holes.
10.Clean bearings and bearing races.
11.Lubricate a new oil seal with gearbox oil.
12.Fit oil seal using a suitable mandrel.
13.Fit input shaft front bearing track using a press
and suitable mandrel.
14.Apply sealant, Part No. STC 4404 to front cover.
15.Position front cover, apply Loctite 290 to threads
of bolts; fit new bolts and tighten by diagonal
selection to25 Nm (18 lbf.ft).
16.Clean clutch housing mating faces, dowels and
dowel holes.
17.Position clutch housing, fit bolts and tighten by
diagonal selection to75 Nm (55 lbf.ft).
18.Clean bearing sleeve mating faces, dowel and
dowel holes.
19.Position bearing sleeve, fit bolts and tighten to
25 Nm (18 lbf.ft).
20.Examine clutch release fork pivot points for wear
and replace as required.
21.Apply a smear of Molybdenum disulphide grease
to pivot points and position release fork.
22.Fit retaining clip ensuring it locates over pivot
point washer, fit bolt and tighten to10 Nm (7
lbf.ft).23.Clean release bearing and bearing sleeve
mating faces.
24.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
25.Fit release bearing and secure with retaining
peg.
26.Fit gearbox.See this Section.
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37MANUAL GEARBOX
8
REPAIR
12.Remove 13 screws securing tunnel cover.
13.Release and remove tunnel cover.
14.Remove cooling fan.See COOLING SYSTEM,
Repair.
15.Remove air filter.See FUEL SYSTEM, Repair.
16.Remove 2 upper bolts securing clutch housing to
engine.
17.Remove bolt securing shim to clutch housing.
18.Release gearbox breather pipes from clips on
heater hose.
19.Remove starter motor.See ELECTRICAL,
Repair.
20.Remove exhaust front pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
21.Drain gearbox oil.See Adjustment.
22.Drain transfer gearbox oil.See
MAINTENANCE ,
23.Remove 3 nuts securing intermediate silencer to
tail pipe.
24.Release silencer from mounting rubbers, remove
silencer and discard gasket.
25.Mark front and rear propeller shaft to transfer
gearbox flanges for reassembly purposes.
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MANUAL GEARBOX
11
REPAIR Refit
44.Clean gearbox to engine mating faces, dowels
and dowel holes.
45.With assistance raise gearbox on jack and align
to clutch and engine.
46.Fit lower bolts securing clutch housing to engine
and tighten to50 Nm (37 lbf.ft).
NOTE: Do not fit upper bolts at this stage.
47.Fit earth leads and secure with bolt.
48.Connect Lucars to differential lock switch,
multiplug to reverse light switch, position
multiplug to bracket and connect low ratio detect
multiplug - if fitted.
49.Raise gearbox jack and guide transfer gearbox
lever through tunnel.
50.Secure body harness clips to bracket on top of
transfer gearbox.
51.Position battery earth lead to transfer gearbox
and tighten retaining nut.
52.Connect multiplug to speed sensor and secure
harness in clip on transfer gearbox.
53.Position mounting brackets and rubber
mountings, positioning heat shield to LH
mounting and tighten bracket bolts to85 Nm (63
lbf.ft).
54.Position nuts to mountings and tighten to48 Nm
(35 lbf.ft).
55.Remove 3 bolts securing support plate
LRT-99-007to gearbox.
56.Position handbrake cable through heel board.
57.Position clutch slave cylinder, fit bolts and
tighten to25 Nm (18 lbf.ft).
58.Clean propeller shafts and mating faces.
59.Position propeller shafts, align to marks and
tighten nuts to48 Nm (35 lbf.ft).
60.Clean intermediate silencer and tail pipe mating
faces.
61.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts and
tighten to25 Nm (18 lbf.ft).
62.Refill gearbox with oil.See Adjustment.
63.Refill transfer gearbox with oil.See
MAINTENANCE ,
64.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
65.Refit starter motor.See ELECTRICAL, Repair.
66.Fit bolt securing shim plate to clutch housing and
tighten10 Nm (7 lbf.ft).
67.Position heater pipe to gearbox housing, fit
upper bolts securing clutch housing to engine
and tighten to50 Nm (37 lbf.ft).
68.Position gearbox breather pipes to clips on
heater hose.69.Fit air cleaner.See FUEL SYSTEM, Repair.
70.Fit cooling fan.See COOLING SYSTEM,
Repair.
71.Fit and align tunnel cover, fit and tighten screws.
72.Position relay panel, fit spacers and tighten
screws.
73.Position hand-brake lever and tighten bolts to25
Nm (18 lbf.ft).
74.Connect handbrake cable to lever, fit clevis pin,
washer and new split pin.
75.Connect Lucar to hand-brake switch.
76.Position gaiter to handbrake lever and secure
with trim stud.
77.Locate insulation pad over gear levers and fit to
tunnel cover.
78.Align spline marks, fit gear lever to lower lever,
fit washer and secure with retaining nut.
79.Position gear lever cover.
80.Position gearbox tunnel carpet.
81.Fit gear lever and transfer gear lever knobs.
82.Reconnect battery negative lead.
83.Fit battery cover.
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TRANSFER GEARBOX
1
REPAIR BOTTOM COVER - TRANSFER GEARBOX -
RESEAL
Service repair no - 41.20.06
1.Raise vehicle on ramp.
2.Remove 6 bolts securing rear underbelly panel
and remove panel.
3.Drain transfer gearbox oil.
4.Remove 10 bolts securing bottom cover to
transfer gearbox and remove cover.
Refit
5.Clean bottom cover and mating face on transfer
gearbox.
6.Clean bolt threads.
7.Apply Loctite 290 to bolt threads.
8.Apply Hylosil RTV sealant to bottom cover
sealing face.
9.Position bottom cover, fit bolts and tighten to25
Nm (18 lbf.ft).
10.Fill transfer gearbox with oil.
11.Fit rear underbelly panel and tighten bolts.
12.Lower vehicle on ramp.TRANSFER GEARBOX
Service repair no - 41.20.25.99
Remove
1.Position vehicle on a’4 post’ramp
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Select low range gear and leave vehicle in
neutral.
5.Remove gear lever knobs.
6.Remove gearbox tunnel carpet.
7.Remove gear lever cover.
8.Release and remove insulation pad.
9.Remove cubby box.See CHASSIS AND
BODY, Repair.
10.Remove 4 screws securing access panel,
diagnostic plug mounting bracket and place
aside.
11.Remove trim stud and lift up handbrake gaiter for
access to clevis pin.
12.Remove split pin, washer, clevis pin and
disconnect cable from handbrake lever.
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41TRANSFER GEARBOX
2
REPAIR
13.Release handbrake outer cable from heelboard.
14.Remove breather pipe banjo bolt from transfer
gearbox high/low cross shaft housing and
discard sealing washers.
15.Remove retaining clip and disconnect high/low
operating rod from lever.
16.Remove cooling fan.See COOLING SYSTEM,
Repair.
17.Remove front exhaust pipe.See MANIFOLD
AND EXHAUST SYSTEM, Repair.
18.Drain transfer gearbox oil.
19.Remove 3 nuts securing intermediate silencer to
tail pipe.
20.Release intermediate silencer from rubber
mountings and remove silencer from tail pipe,
discard gasket.
21.Using a centre punch, mark relationship between
front propeller shaft and transfer gearbox drive
flanges and rear propeller shaft and brake drum
drive flanges.
22.Remove 4 nuts securing front propeller shaft to
transfer gearbox drive flange and remove
propeller shaft.
23.Remove 4 nuts securing rear propeller shaft to
brake drum flange.
24.Release propeller shaft and tie aside.
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TRANSFER GEARBOX
5
REPAIR
43.If transfer gearbox is to be refitted, remove and
discard input shaft oil seal.
Refit
44.Clean mating faces of main gearbox extension
case and transfer gearbox.
45.Remove all traces of sealant from threads of
transfer gearbox securing bolts and studs.
46.Clean input shaft oil seal recess in transfer
gearbox.
47.Lubricate new input shaft oil seal with transfer
gearbox oil.
48.Using toolLRT-37-014, fit input shaft oil seal, lip
side facing inwards.49.Ensure guide studsLRT-41-009are fitted in
main gearbox extension case.
CAUTION: If securing studs were removed
during transfer gearbox removal, apply
Loctite 290 to threads of new studs; fit
studs and tighten to 45 Nm (33 lbf.ft).
50.Secure transfer gearbox to support plate
LRT-99-010, fit and tighten 4 bolts.
51.Raise transmission hoist until transfer gearbox
can be located over guide studsLRT-41-009.
52.Apply Loctite 290 to threads of securing bolts
and studs.
53.Fit and lightly tighten 2 nuts to secure transfer
gearbox to main gearbox extension case.
54.Remove guide studsLRT-41-009.
55.Ensuring bolts are in their original fitted
locations, fit and lightly tighten 4 bolts to secure
transfer gearbox to main gearbox extension
case.
56.Progressively tighten nuts and bolts to45 Nm
(33 lbf.ft).
57.Position earth leads to RH side of transfer
gearbox, fit and tighten bolt.
58.Connect low ratio detect switch multiplug and
secure to bracket. Connect Lucars to differential
lock warning lamp switch.
59.Raise gearbox jack and guide transfer gearbox
lever through tunnel.
60.Connect body harness clips to bracket on top of
transfer gearbox.
61.Position earth lead to transfer gearbox, tighten
nut to45 Nm (33 lbf.ft).
62.Connect speed sensor multiplug and secure
harness in clip.
63.Position heat shield to LH mounting, fit
mountings and brackets and tighten bolts to85
Nm (63 lbf.ft).
64.Fit nuts securing RH and LH mountings and
tighten to48 Nm (35 lbf.ft).
65.Position breather pipe to transfer gear box, fit
new sealing washers and tighten banjo bolts to
15 Nm (11 lbf.ft).
66.Remove bolts securing support plate to gearbox
jack.
67.Remove bolts securingLRT-99-010to transfer
gearbox.
68.Apply Loctite 290 to threads of bottom cover
securing bolts, fit bolts and tighten to25 Nm (18
lbf.ft)
69.Position differential lock control rod and secure
with retaining clip.
70.Clean rear propeller shaft to brake drum flange
mating faces.
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