oil LAND ROVER DEFENDER 1999 Workshop Manual

41TRANSFER GEARBOX
6
REPAIR 71.Release propeller shaft, align flange markings
and connect to studs.
72.Fit nuts securing propeller shaft and tighten to48
Nm (33 lbf.ft).
73.Clean front propeller to transfer gearbox flange
mating faces.
74.Fit propeller shaft, align flange markings and
tighten nuts to48 Nm (33 lbf.ft).
75.Using new gasket, fit intermediate silencer and
tighten nuts to25 Nm (18 lbf.ft).
76.Fit exhaust front pipe.See MANIFOLD AND
EXHAUST SYSTEM, Repair.
77.Refill transfer gearbox with recommended oil.
78.Fit cooling fan cowl.
79.Fit high/low operating rod and secure with
retaining clip.
80.Position handbrake outer cable to heelboard.
81.Position handbrake cable to lever, fit clevis pin,
washer and new split pin.
82.Position handbrake gaiter and secure with trim
studs.
83.Fit insulation pad to tunnel.
84.Fit gear lever cover.
85.Fit gear lever knobs.
86.Position diagnostic plug bracket, access panel
and tighten screws.
87.Fit carpet to transmission tunnel.
88.Fit cubby box.See CHASSIS AND BODY,
Repair.
89.Fit cooling fan.See COOLING SYSTEM,
Repair.
90.Reconnect battery negative lead.
91.Fit battery cover.GASKET - REAR COVER PLATE
Service repair no - 41.20.30
Remove
1.Raise vehicle on’4 post ramp’.
2.Mark rear cover plate to bearing housing for
assembly purposes.
3.Noting fitted position of stud bolt and harness
clip bracket, remove 5 bolts and stud bolt
securing cover plate.
4.Collect harness clip bracket.
5.Remove cover plate.
Refit
6.Clean cover plate and mating face.
7.Apply Hylosil RTV 102 to rear cover mating face.
8.Align reference marks, fit cover plate.
9.Clean cover bolts and apply Loctite 290 threads
of bolts and stud nut.
10.Position clip bracket, fit stud nut and bolts,
tighten by diagonal selection to25 Nm (18
lbf.ft).
11.Check/top-up transfer gearbox oil.
12.Lower vehicle.
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41TRANSFER GEARBOX
8
REPAIR 17.Apply Hylomar PL32 sealant to switch threads.
18.Position switch into gearbox housing until
locknut/spacer bottoms out on housing.
19. Switches fitted with spacer:Tighten spacer
securing differential lock switch to11 Nm (8
lbf.ft).
20.Connect Lucars to switch.
21. Switches fitted with locknut:Adjust switch.
See Adjustment.
22.Fit and align tunnel cover, fit and tighten screws.
23.Fit hand-brake lever and tighten bolts to25 Nm
(18 lbf.ft).
24.Secure bulkhead carpet to LH side of tunnel.
25.Position relay/fuse panel, fit spacers and tighten
screws.
26.Fit insulation pad around gear levers.
27.Fit gear lever (s) gaiter.
28.Fit gearbox tunnel carpet.
29.Fit gear lever knobs.
30.Reconnect battery negative lead.
31.Fit battery cover.SEAL - INPUT SHAFT
Service repair no - 41.20.50
Remove
1.Remove transfer gearbox.See this Section.
2.Remove and discard input shaft oil seal from
transfer gearbox.
Refit
3.Clean oil seal recess in transfer gearbox.
4.Lubricate new oil seal with transfer gearbox oil.
5.UsingLRT-37-014, fit input shaft seal to transfer
gearbox.
6.Fit transfer gearbox.See this Section.
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TRANSFER GEARBOX
9
REPAIR SEAL - FRONT OUTPUT SHAFT
Service repair no - 41.20.51
Remove
1.Position vehicle on 4 post ramp.
2.Remove underbelly panelSee CHASSIS AND
BODY, Repair.
3.Mark front propeller shaft to transfer gearbox
flanges for reassembly purposes.
4.Remove and discard 4 nuts securing front
propeller shaft to transfer gearbox drive flange,
and release propeller shaft from flange.
5.Restrain transfer gearbox drive flange using
LRT-51-003, remove and discard drive flange
nut, remove and discard steel and felt washers.
6.UsingLRT-99-500if necessary remove drive
flange from transfer gearbox.
7.Remove and discard front input shaft oil seal
from transfer gearbox.
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41TRANSFER GEARBOX
10
REPAIR Refit
8.Clean oil seal recess.
9.Lubricate new input shaft oil seal with transfer
gearbox oil.
10.Fit oil seal usingLRT-41-012.
NOTE: Use end of tool marked ’FRONT’ to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit new drive flange nut and
tighten to148 Nm (109 lbf.ft).
13.Align marks and position front propeller shaft to
output flange. Fit new nuts and tighten to48 Nm
(35 lbf.ft).
14.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
15.Check/top-up transfer gearbox oil.SEAL - REAR OUTPUT SHAFT
Service repair no - 41.20.54
Remove
1.Loosen brake shoe adjuster bolt.
2.Remove rear propeller shaft.See PROPELLER
SHAFTS, Repair.
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TRANSFER GEARBOX
11
REPAIR
3.Remove screw securing brake drum.
4.Remove brake drum.
5.Restrain transfer gearbox drive flange using
LRT-51-003, remove and discard drive flange
nut, remove and discard steel and felt washers.
6.UsingLRT-99-500if necessary, remove drive
flange from transfer gearbox.
7.Remove and discard rear output shaft oil seal
from transfer gearbox.
Refit
8.Clean seal recess.
9.Lubricate new oil seal with transfer gearbox oil.
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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 ,
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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
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REAR AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication from the hub seals can
be caused by a faulty internal seal. For example, if the
seals which separate the differential from the hubs are
faulty and the vehicle is operating or parked on an
embankment, oil from the differential may flood one
hub resulting in a lack of lubrication in the differential.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See’Description and Operation’for illustrations of oil
seal locations.
When investigating hub seal leaks check the grease
for dilution with oil. Also check the differential oil level,
for signs of metal particles in the oil and the condition
of internal seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential oil level, giving a false impression that
the housing has been over filled.
Do not assume that a high oil level in the
differential is due to over filling or, that a low level
is because of an external leak.
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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.
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51REAR AXLE AND FINAL DRIVE
2
REPAIR Refit
15.Position axle and fit lower links. Tighten fixings
to176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair. Anti-roll bar
links.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten to correct torque:
Alloy wheels -130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy Duty wheels -170 Nm (125 lbf/ft)
24.Remove rear chassis support.
25.Bleed brake systemSee BRAKES, Repair.
brake system bleed.
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