Defender 90 NAS. Manual — part 36
TRANSFER GEARBOX
7
REPAIR
SHIFTLOCK SOLENOID
Service repair no - 41.20.63
Remove
1. Remove centre console.
See CHASSIS AND
BODY, Repair, Centre console
2. Remove carpet from transmission tunnel.
3. Remove 2 screws securing relay panel.
4. Retain 2 centre console screw brackets and
spacers.
5. Release connector J1962 from bracket on tunnel
cover and move relay panel aside to gain access
to tunnel cover top fixings.
6. Remove 15 screws securing tunnel cover.
7. Release and remove tunnel cover.
8. Disconnect shiftlock solenoid multiplug.
9. Remove 4 bolts and release solenoid cover from
transfer box.
10. Remove solenoid and washer.
11. Clean joint sealant from mating faces.
Refit
12. Apply Hylosil or equivalent sealant to mating
faces.
13. Fit solenoid. Ensure solenoid multiplug lead is
located in cover recess.
14. Secure solenoid cover to transfer box. Tighten
bolts to
9 Nm (7 lbf/ft).
15. Connect solenoid multiplug.
16. Fit tunnel cover.
17. Secure connector J1962 to bracket on tunnel
cover.
18. Position centre console screw bracket and
spacers and fit relay panel.
19. Fit tunnel carpet.
20. Fit centre console.
See CHASSIS AND BODY,
Repair, Centre console
41
TRANSFER GEARBOX
8
REPAIR
NEUTRAL SWITCH
Service repair no - 41.20.64
Remove
1. Remove centre console.
See CHASSIS AND
BODY, Repair, Centre console
2. Remove carpet from transmission tunnel.
3. Remove 2 screws securing relay panel.
4. Retain 2 centre console screw brackets and
spacers.
5. Release connector (J1962) from bracket on
tunnel cover and move relay panel aside to gain
access to tunnel cover top fixings.
6. Remove 15 screws securing tunnel cover.
7. Release and remove tunnel cover.
8. Disconnect neutral switch multiplug.
9. Remove neutral switch from transfer box.
10. Clean sealant from switch.
Refit
11. Apply Hylomar PL32/L20 or equivalent sealant to
neutral switch.
12. Fit switch to transfer box and tighten to
25 Nm
(18 lbf/ft).
13. Connect switch multiplug.
14. Fit tunnel cover.
15. Secure connector (J1962) to bracket on tunnel
cover.
16. Position centre console screw bracket and
spacers and fit relay panel.
17. Fit tunnel carpet.
18. Fit centre console.
See CHASSIS AND BODY,
Repair, Centre console
TRANSFER GEARBOX
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
LT230Q Transfer gearbox
Nm
lbf ft
Bottom cover to transfer case
25
. . . . . . . . . . ..
18
Transfer breather
15
. . . . . . . . . . . . . . . .
11
Transfer box front drive flange to drive shaft
45
. . . . .
33
Transfer box rear drive flange to drive shaft
45
. . . . . .
33
Transfer box to gearbox extension case
45
. . . . . . ..
33
NOTE: The following torque values are for screws and bolts not specified in the previous table.
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
1/4
9
. . . . . . . . . . . . . . . . . . ...
7
5/16
25
. . . . . . . . . . . . . . . . . . .
18
3/8
40
. . . . . . . . . . . . . . . . . . ...
30
7/16
80
. . . . . . . . . . . . . . . . . . .
60
1/2
90
. . . . . . . . . . . . . . . . . . ...
65
5/8
135
. . . . . . . . . . . . . . . . . . ...
100
AUTOMATIC GEARBOX
1
DESCRIPTION AND OPERATION
DESCRIPTION
The automatic transmission is specially tailored version of the ZF 4HP22, used by many manufacturer’s of high
performance vehicles.
A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third
gears are reduction ratios but fourth is an overdrive gear for high speed cruising. A direct drive clutch, integral with
the torque converter operates to engage fourth gear.
The gear selector has seven positions as follows:
P = Park provides a mechanical lock on the output shaft.
R = Reverse gear.
N = Neutral.
D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1.
3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1.
2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1.
1 = Provides a 1st gear start with no up shifts, or 3-2-1.
All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output
shaft.
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