Defender 90 NAS. Manual — part 41
44
AUTOMATIC GEARBOX
2
REPAIR
20. Locate selector linkage setting gauge
LRT-44-002in position and gently press control
unit forwards as shown. Tighten bolts to
8 Nm, 6
lbf ft.
21. Remove setting gauge.
22. Refit gearbox fluid pan
See Fluid pan gasket
and screen.
23. Lower vehicle on ramp [hoist].
24. Adjust kickdown cable
See Adjustment,
Kickdown cable adjustment.
25. Reconnect battery negative lead.
26. Refill gearbox oil using correct grade of oil
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids.
INHIBITOR SWITCH
Service repair no - 44.15.19
Remove
1. Site vehicle on a four post ramp [hoist].
2. Disconnect battery negative lead. Raise vehicle.
3. Disconnect inhibitor switch multiplug.
4. Remove inhibitor switch retaining plate.
5. Remove inhibitor switch.
6. Remove ’O’ ring seal.
7. Clean inhibitor switch.
Refit
8. Clean mating face on casing.
9. Fit and lubricate NEW ’O’ ring seal to switch.
10. Fit switch to casing.
11. Secure with retaining plate and bolt.
12. Connect multiplug to harness.
13. Reconnect battery and remove vehicle from
ramp [hoist].
AUTOMATIC GEARBOX
3
REPAIR
FLUID PAN GASKET AND SCREEN
Service repair no - 44.24.05 - Fluid pan gasket
Service repair no - 44.24.07 - Fluid screen
Remove
1. Site vehicle on a four post ramp [hoist].
2. Disconnect battery negative lead.
3. Raise vehicle.
4. Drain fluid and refit plug with new seal. Tighten
to
43 Nm, 32 lbf ft.
5. Remove catalytic converter assembly
See
EMISSION CONTROL, Repair, Front
pipe/catalytic converter.
6. Release fuel pipes from retaining clip secured by
top RH chassis crossmember bolt.
7. Remove 8 bolts securing chassis crossmember.
8. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
9. Disconnect dipstick tube from fluid pan. Loosen
securing bolt at bell housing and move tube
aside.
10. Remove clamps securing fluid pan. Note their
locations for refit and withdraw pan.
11. Remove gasket and clean gasket mating faces.
12. Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard ’O’ ring seal.
13. Detach suction pipe from fluid screen, discard
’O’ ring seal.
Refit
14. Clean fluid screen and blow out with airline.
15. Clean suction pipe.
16. Fit new ’O’ ring seals to fluid screen using light
grease to aid assembly.
17. Fit fluid screen and suction pipe with spacer and
secure with bolts. Tighten to
8 Nm, 6 lbf ft.
18. Refit fluid pan using a NEW gasket. Tighten to
8
Nm, 6 lbf ft.
19. Connect dipstick tube to fluid pan, tighten bolt at
bell housing. Filler tube union nut Tighten to
70
Nm, 52 lbf ft.
20. Position both exhaust heat shields and refit
chassis cross-member. Secure fuel pipes to
retaining clip.
21. Refit catalytic converter assembly
See
EMISSION CONTROL, Repair, Front
pipe/catalytic converter.
22. Connect battery.
23. Refill transmission using correct grade of fluid
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids.
24. Apply parking brake and with selector at ’P’, run
engine at idle.
25. Apply footbrake, from ’P’, move selector to
position ’1’ and back to ’N’. Check fluid level, this
must be between the level marks. Top-up as
necessary.
44
AUTOMATIC GEARBOX
4
REPAIR
TORQUE CONVERTER
Service repair no - 44.17.04
Remove
1. Remove gearbox and transfer box assembly,
See Gearbox and transfer box assembly
2. Place gearbox on bench. Remove torque
converter using torque converter handle
LRT-44-010, taking care not to damage torque
converter/oil pump housing oil seal.
Refit
3. Fit NEW torque converter using torque converter
handles LRT-44-010. Check dimension from
converter fixing boss to converter housing face is
50 mm, 1.968 in. This shows converter is
correctly seated in housing.
4. Refit gearbox and transfer box assembly.
See
Gearbox and transfer box assembly
PUMP AND MAIN HOUSING
Service repair no - 44.20.11 - Intermediate plate
gasket
Service repair no - 44.32.01 - Pump assembly
Service repair no - 44.32.07 - Pump oil seal
Remove
1. Remove gearbox and transfer box assembly,
See Gearbox and transfer box assembly
2. Place gearbox on bench. Remove torque
converter using torque converter handles
LRT-44-010, taking care not to damage torque
converter/oil pump housing oil seal.
3. Remove 12 bolts (inner ring of bolts).
4. Remove bell housing and pump assembly,
discard gasket.
5. Remove 8 bolts from rear of pump.
AUTOMATIC GEARBOX
5
REPAIR
6. Screw in 2 bolts, diagonally opposite each other.
Tap lightly using a soft headed mallet to remove
pump assembly from intermediate plate.
7. Remove shaft sealing ring and ’O’ ring from
pump housing and discard.
Refit
8. Using oil seal replacer LRT-44-001 fit shaft seal
ring into pump housing.
9. Fit ’O’ ring onto circumference of pump housing.
10. Align dowel with hole in intermediate plate and
press pump housing home.
11. Fit pump housing to intermediate plate, tighten
bolts to
10 Nm, 7 lbf ft.
12. Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LRT-44-003(LST111),
check that pump gears rotate freely.
13. Before fitting intermediate plate and bell housing
assembly, check that thrust washer and axial
cage are seated on clutch housing.
14. Place NEW gasket and selective disc washer
onto bell housing and intermediate plate
assembly using Petroleum Jelly.
15. Fit bell housing and intermediate plate assembly
to gearcase. Tighten bolts to
46 Nm, 34 lbf ft.
16. Place end float gauge LRT-44-003 onto pump
housing and check that axial play is between 0.2
- 0.4 mm, 0.008 - 0.016 in. Replace existing
washer, situated at rear of intermediate plate,
with a washer selected to give required end float.
17. Refit torque converter into housing using torque
converter handles LRT-44-010. Check that
dimension from converter fixing bolt boss to
converter housing face is 50 mm, 1.968 in to
comfirm that converter is properly seated in
housing.
18. Refit gearbox/transfer box assembly.
See
Gearbox and transfer box assembly
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