Defender 90 NAS. Manual — part 42
44
AUTOMATIC GEARBOX
6
REPAIR
GEARBOX AND TRANSFER BOX ASSEMBLY
Service repair no - 44.20.04/99
Remove
1. Position vehicle on ’4-post’ ramp.
2. Select LOW range gear and leave vehicle in
neutral.
3. Disconnect battery negative lead.
4. Drain gearbox oil.
See SECTION 10,
Maintenance, under vehicle maintenance
5. Drain transfer gearbox oil.
See SECTION 10,
Maintenance, under vehicle maintenance
6. Remove centre console.
See CHASSIS AND
BODY, Repair, centre console
7. Remove carpet from transmission tunnel.
8. Remove hi-low selector housing cover from
tunnel.
9. Working through hi-low gear lever aperture,
disconnect inhibitor/reverse light switch
multiplug.
10. Remove 2 cable ties securing gearbox and
transfer box breather pipes to harness.
11. Remove 3 trim studs securing hand brake gaiter.
12. Release hand brake gaiter to access cable
linkage.
13. Remove split pin and clevis pin securing hand
brake cable to lever.
14. Remove 2 screws securing fan cowl to upper
retaining brackets.
15. Release 2 clips securing upper fan cowl.
16. Remove upper fan cowl.
AUTOMATIC GEARBOX
7
REPAIR
17. Remove kick-down cable clevis pin.
18. Release kick-down outer cable lock nut.
19. Release kick-down outer cable from abutment
bracket.
20. Release kick-down outer cable from clip on rear
of LH cylinder head.
21. Remove bolt securing 2 breather pipe ’P’ clips to
rear of RH cylinder head.
22. Remove 6 bell housing to engine bolts.
23. Raise vehicle.
24. Remove exhaust front pipe.
See EMISSION
CONTROL, Repair, front pipe/catalytic
converter
25. Remove 2 nuts securing intermediate pipe to tail
pipe.
26. Release intermediate pipe from tail pipe and
remove from mounting.
27. Remove 8 bolts securing chassis crossmember.
28. With assistance, and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
29. Remove crossmember.
30. Remove body jack.
31. Remove bolt securing LH and RH catalyst heat
shields to chassis.
32. Remove catalyst heat shields.
44
AUTOMATIC GEARBOX
8
REPAIR
33. Using a centre punch, mark relationship between
front propeller shaft to transfer box flanges.
34. Using a centre punch, mark relationship between
rear propeller shaft to brake drum flanges.
35. Remove 4 nuts securing front propeller shaft to
transfer box flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
36. Release propeller shaft from transfer box flange
bolts and tie aside.
37. Remove 4 nuts securing rear propeller shaft to
brake drum flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
38. Release propeller shaft from brake drum bolts
and tie aside.
39. Remove 7 bolts securing bell housing closing
plate and remove plate.
40. Remove 3 bolts securing bell housing access
plate and remove plate.
41. Mark relationship between converter and drive
plate.
42. Rotate crankshaft to access drive plate to
converter fixing.
43. Remove 4 bolts securing drive plate to
converter.
44. Fit suitable piece of wood through bell housing
access hole to retain converter.
AUTOMATIC GEARBOX
9
REPAIR
45. Remove clamp bolt securing gearbox cooler
pipes to engine sump bracket.
46. Loosen gearbox cooler pipe unions and
disconnect from gearbox.
47. Remove and discard ’O’ rings from pipes.
CAUTION: Plug the connections.
48. Tie cooler pipes aside.
49. Loosen gearbox filler tube union and remove
from fluid pan.
50. Remove and discard ’O’ ring from union.
CAUTION: Plug the connections.
51. Remove split pin from selector cable yoke and
collect washer.
52. Release yoke from lever.
53. Remove bolt securing selector outer cable clamp
to transfer box LH mounting.
54. Remove nut securing oxygen sensor multiplug
bracket from transfer box earth bolt and collect
bracket.
55. Remove nut securing earth strap to transfer box
and release strap.
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