Defender 90 NAS. Manual — part 43
44
AUTOMATIC GEARBOX
10
REPAIR
56. Release hand brake outer cable from body.
57. Remove bolt securing earth lead to RH side of
transfer box.
58. Fit transmission cradle LRT-99-008A to
transmission jack.
59. Fit and tighten bolts securing cradle to jack.
60. Remove 2 lower bolts securing transfer box rear
cover.
61. Collect hand brake cable heat shield.
62. Raise jack and align cradle to transmission.
63. Refit previously removed transfer box rear cover
bolts to secure cradle.
64. Remove 2 nuts and bolts securing heat shield to
transfer box LH mounting bracket.
65. Remove heat shield.
66. Remove 3 nuts and bolts securing transfer box
LH mounting bracket to chassis.
67. Release earth lead from fixing.
68. Remove nut securing transfer box RH mounting.
69. Remove 3 nuts and bolts securing transfer box
RH mounting bracket to chassis.
70. Remove transfer box RH mounting bracket and
collect flexible mount heat shield.
71. Lower transmission on jack to access harness
connectors.
AUTOMATIC GEARBOX
11
REPAIR
72. Disconnect the following multiplugs/connectors
from transfer box:
Speed transducer
Parking solenoid
Neutral detection switch
Differential lock
Temperature sensor switch
73. Remove 2 cable ties securing harness to
transfer box.
74. Position jack to support engine sump.
CAUTION: Use a block of wood or hard
rubber pad to protect sump.
75. Remove 2 remaining bell housing to engine
bolts.
76. With assistance, lower transmission and engine
jacks until hi-low selector lever is clear of
transmission tunnel aperture.
77. Separate transmission from engine and lower on
jack.
78. Remove transmission assembly from beneath
ramp.
79. Position lifting eyes to transmission and secure
with bolts.
80. Fit lifting chains to eyes and connect.
81. Position lifting hoist and connect lifting chains.
82. Raise hoist until chains are taught.
83. Remove bolts securing cradle to transfer box.
84. Raise transmission from cradle.
85. Refit transfer box rear cover plate bolts.
86. Lower transmission assembly onto work bench.
87. Disconnect lifting chains from eyes.
88. Remove bolts securing eyes to transmission and
remove eyes.
Refit
89. Position lifting eyes to transmission and secure
with bolts.
90. Connect lifting chains to eyes.
91. Raise transmission assembly from bench and
position above transmission cradle.
92. Remove 2 transfer box rear cover plate bolts.
93. Lower transmission onto cradle, align to transfer
box rear cover plate and secure with previously
removed bolts.
94. Lower hoist and disconnect lifting chains from
eyes.
95. Remove chains from hoist.
96. Remove bolts securing lifting eyes to
transmission and remove eyes.
97. Position transmission assembly beneath vehicle.
98. Clean engine to gearbox mating faces.
99. Clean engine to gearbox dowels and dowel
holes.
100. With assistance, raise transmission on jack and
position to engine dowels.
101. Fit 2 lower bell housing to engine bolts and
tighten to
45 Nm, 33 lbf ft.
102. With assistance, raise engine and transmission
jacks to position transmission assembly.
NOTE: Do not fully raise transmission at
this stage as access is required for
connection of connectors to transfer box.
103. Remove engine jack from beneath vehicle.
104. Secure harness to transfer box with cable ties.
105. Connect multiplugs/connectors to transfer box.
106. Raise transmission and align to mounting
locations.
107. Fit transfer box RH flexible mounting heat shield
and mounting bracket.
108. Align RH mounting to chassis and secure with
nuts and bolts.
109. Fit and tighten nut securing RH mounting.
110. Align LH mounting to chassis and secure with
nuts and bolts.
NOTE: Position earth lead to mounting
fixing.
111. Position heat shield to LH mounting bracket and
secure with fixings.
112. Remove bolts securing transmission cradle to
transfer box.
113. Lower transmission jack and remove from
beneath ramp.
114. Fit and tighten transfer box rear cover bolts.
NOTE: Position heat shield to cover plate
fixing.
115. Position earth lead to RH side of transfer box
and secure with bolt.
116. Feed hand brake outer cable through body.
NOTE: Apply a soap solution to aid fitment
of cable to body.
117. Position earth strap to transfer box stud and
secure with nut.
118. Fit oxygen sensor multiplug bracket to transfer
box earth bolt and secure with nut.
44
AUTOMATIC GEARBOX
12
REPAIR
119. Position selector outer cable clamp to transfer
box LH mounting and secure with bolt.
120. Position selector cable yoke to lever, fit washer
and secure with split pin.
121. Remove plug from transmission filler tube union.
122. Lubricate new ’O’ ring with gearbox oil and fit to
filler tube.
123. Fit filler tube to gearbox and tighten union.
124. Release cooler pipes and remove plugs from
connections.
125. Lubricate new ’O’ rings with gearbox oil and fit to
pipes.
126. Position cooler pipes to gearbox and tighten
unions.
127. Position cooler pipes to engine sump bracket, fit
clamp and secure with bolt.
128. Remove piece of wood from bell housing access
hole.
129. Align converter to drive plate.
130. Fit bolts securing converter to drive plate and
tighten to
45 Nm, 33 lbf ft.
NOTE: Rotate crankshaft during the above
procedure.
131. Fit bell housing access plate and secure with
bolts tightened to
9 Nm, 7 lbf ft. .
132. Clean bell housing cover plate and mating face.
133. Fit plate and secure with bolts tightened to
9
Nm, 7 lbf ft.
134. Clean rear propeller shaft to brake drum mating
faces.
135. Release rear propeller shaft, align flange
markings and connect to studs.
136. Fit nuts securing rear propeller shaft to brake
drum and tighten to
47 Nm, 35 lbf ft.
NOTE: Rotate propeller shaft to gain
access to all fixings.
137. Clean front propeller shaft to transfer box mating
faces.
138. Release front propeller shaft, align flange
markings and connect to studs.
139. Fit nuts securing front propeller shaft to transfer
box and tighten to
47 Nm, 35 lbf ft.
NOTE: Rotate propeller shaft to gain
access to all fixings.
140. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
141. Fit crossmember and align fixings.
142. Remove body jack.
143. Fit nuts and bolts securing chassis
crossmember, but do not tighten.
144. Fit LH and RH catalyst heat shields to chassis, fit
bolts but do not tighten.
145. Align LH and RH catalyst heat shields to chassis
crossmember fixings and tighten all fixings.
146. Clean intermediate to tail pipe flange.
147. Fit intermediate pipe to mounting rubber,
connect to tail pipe and secure with nuts.
148. Fit exhaust front pipe.
See EMISSION
CONTROL, Repair, front pipe/catalytic
converter; Refit
149. Lower vehicle.
150. Fit bolts securing bell housing to engine and
tighten to
46 Nm .
NOTE: Align harness brackets to 2
uppermost bell housing retaining bolts.
151. Align breather pipe ’P’ clips to rear of RH
cylinder head and secure with bolt.
152. Secure kick-down outer cable to clip on rear of
LH cylinder head.
153. Secure kick-down outer cable to abutment
bracket.
154. Secure kick-down outer cable lock nut.
155. Align kick-down cable to linkage and secure
clevis pin.
156. Adjust kick-down cable.
See Adjustment,
kickdown cable adjustment
157. Fit upper fan cowl and secure with clips.
158. Align fan cowl to upper retaining brackets and
secure with screws.
159. Align hand brake cable to lever, fit clevis pin and
secure with split pin.
160. Position hand brake gaiter and secure with trim
studs.
161. Secure gearbox and transfer box breather pipes
to harness with cable ties.
162. Connect inhibitor/reverse light switch multiplug.
163. Fit hi-low selector housing cover to tunnel.
164. Fit carpet to transmission tunnel.
165. Fit centre console.
See CHASSIS AND BODY,
Repair, centre console
166. Refill transfer gearbox oil.
See SECTION 10,
Maintenance, under vehicle maintenance
167. Refill gearbox oil.
See SECTION 10,
Maintenance, under vehicle maintenance
168. Reconnect battery negative lead.
169. Select Hi range gear and park.
170. Remove vehicle from ramp.
AUTOMATIC GEARBOX
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
Nm
lbf ft
Coupling shaft to mainshaft
42*
. . . . . . . . . . . ..
30*
Filler tube to sump
68
. . . . . . . . . . . . . . .
50
Gear change lever to gearbox
25
. . . . . . . . . . ..
18
Cooler pipe adaptor to gearbox
42
. . . . . . . . . .
30
Securing screws - clutch F
10
. . . . . . . . . . . ...
7
Securing screw - parking pawl
10
. . . . . . . . . . .
7
Securing screws - pump
10
. . . . . . . . . . . . ...
7
Intermediate plate plugs (M20)
50
. . . . . . . . . .
35
Intermediate plate plugs (M14)
40
. . . . . . . . . .
30
Bell housing mounting bolts
46
. . . . . . . . . . . .
34
Governor mounting screws
10
. . . . . . . . . . . ..
7
Extension housing bolts
23
. . . . . . . . . . . . ...
17
Control unit mounting bolts
8
. . . . . . . . . . . ..
6
Draib plug - fluid pan
10
. . . . . . . . . . . . . .
7
Mounting screws for sump
8
. . . . . . . . . . . ...
6
Drive plate to converter
39*
. . . . . . . . . . . . .
29*
Gearbox to engine
42
. . . . . . . . . . . . . . .
31
Strut (threaded end)
42
. . . . . . . . . . . . . . .
31
Bottom cover to converter housing
9
. . . . . . . . ..
7
Cover - converter housing
9
. . . . . . . . . . . .
7
Drive plates to crankshaft adaptor
40*
. . . . . . . . ...
30*
Adaptor to crankshaft
84
. . . . . . . . . . . . . ...
62
NOTE: * These bolts MUST have threads coated with Loctite 270 prior to assembly.
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC
Nm
lbf ft
M5
6
. . . . . . . . . . . . . . . . . . ...
5
M6
9
. . . . . . . . . . . . . . . . . . ...
7
M8
25
. . . . . . . . . . . . . . . . . . ...
18
M10
45
. . . . . . . . . . . . . . . . . . .
33
M12
90
. . . . . . . . . . . . . . . . . . .
65
M14
105
. . . . . . . . . . . . . . . . . . .
75
M16
180
. . . . . . . . . . . . . . . . . . .
130
UNC / UNF
Nm
lbf ft
1/4
9
. . . . . . . . . . . . . . . . . . ...
7
5/16
24
. . . . . . . . . . . . . . . . . . .
18
3/8
39
. . . . . . . . . . . . . . . . . . ...
28
7/16
78
. . . . . . . . . . . . . . . . . . .
58
1/2
90
. . . . . . . . . . . . . . . . . . ...
65
5/8
136
. . . . . . . . . . . . . . . . . . ...
100
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