washer LAND ROVER DEFENDER 1999 Repair Manual

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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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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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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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
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