Defender 300Tdi (1996+). Manual — part 13
MAINTENANCE
11
MAINTENANCE
RENEW GEARBOX OIL
1. Ensure vehicle is level.
2. Place suitable tray under gearbox.
3. Disconnect battery.
4. Clean area around filler/level plugs.
5. Remove both plugs and allow oil to drain
completely.
WARNING: When draining gearbox, care
should be taken to ensure that oil is not
hot as personal scalding could result.
6. Refit drain plug and tighten to
30 Nm (22 lbf/ft).
7. Inject new oil into gearbox until it runs out of filler
hole. Allow excess oil to drain and wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
8. Refit filler/level plug and tighten to
30 Nm (22
lbf/ft).
9. Reconnect battery.
RENEW TRANSFER GEARBOX OIL
1. Ensure vehicle is level.
2. Disconnect battery.
3. Clean area around filler/level and drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4. Place suitable tray under transfer gearbox.
5. Remove filler/level plug to vent gearbox and
assist draining.
6. Remove drain plug and allow oil to drain.
7. Thoroughly clean drain plug threads and apply
fresh ’Hylomar’ sealant.
8. Refit drain plug and tighten to
30 Nm (22lbf/ft).
9. Inject new oil of correct quantity and grade into
gearbox until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
10. Thoroughly clean filler/level plug and apply fresh
’Hylomar’ sealant.
11. Refit plug and tighten to
30 Nm (22 lbf/ft).
12. Reconnect battery.
CHECK/TOP UP TRANSFER GEARBOX OIL
1. Ensure vehicle is level.
2. Disconnect battery.
3. Clean area around filler/level plug.
4. Remove plug, check oil level and top up if
necessary with correct grade of oil,
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids until oil runs out from filler/level hole.
Allow excess oil to drain and wipe clean.
5. Thoroughly clean filler/level plug threads and
apply fresh ’Hylomar’ sealant.
6. Refit plug and tighten to
30 Nm (22 lbf/ft).
7. Reconnect battery.
10
MAINTENANCE
12
MAINTENANCE
RENEW FRONT AND REAR AXLE OIL
1. Ensure vehicle is level and place suitable tray
under axle to be drained.
2. Using 13mm square drive wrench, remove drain
and filler/level plugs from axle and allow oil to
drain completely.
3. Clean and refit drain plug.
A - Front and rear axle, 90 models, front, 110/130
models. B - Rear axle, 110/130 models.
4. Inject new oil,
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended lubricants and fluids until it
runs out from filler/level hole. Allow excess oil to
drain and wipe clean.
5. Clean and refit filler/level plug.
CHECK/TOP UP FRONT AND REAR AXLE
1. Ensure vehicle is level.
2. Using 13 mm square drive wrench, remove
filler/level plug.
3. If necessary inject new oil until oil runs out from
filler/level hole. Allow excess oil to drain and
wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
4. Clean and refit filler/level plug.
RENEW SWIVEL PIN HOUSING OIL
1. Ensure vehicle is level and place suitable tray
under swivel to be drained.
2. Remove drain and level plugs, allow oil to drain
completely. Clean and refit drain plug.
3. Remove filler plug and inject new oil until oil runs
out from level hole.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids Allow
excess oil to drain and wipe clean.
4. Clean and refit filler and level plugs.
NOTE: On later vehicles, the level and
drain plugs have been deleted. The swivel
pin housing is filled with grease on
manufacture, for life service, and maintenance is
not required.
CHECK/TOP UP SWIVEL PIN HOUSING OIL
1. Ensure vehicle is level.
2. Remove level and filler plug, check oil level and
top up if necessary with new oil until oil runs out
from level hole. Allow excess oil to drain and
wipe clean.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
3. Clean and refit filler and level plugs.
MAINTENANCE
13
MAINTENANCE
LUBRICATE PROPELLER SHAFT UNIVERSAL
AND SLIDING JOINTS
1. Clean all grease nipples on front and rear
propeller shafts.
2. Using a low pressure hand grease gun, apply
recommended grease
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids to grease
nipples at front and rear propeller shaft universal
and sliding joints.
VISUALLY CHECK BRAKE, FUEL, CLUTCH
HOSES/PIPES/UNIONS FOR CHAFING, LEAKS
AND CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
RENEW CATALYTIC CONVERTERS
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
manifolds and exhaust system
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF BALL JOINTS AND DUST COVERS
Ball joints are lubricated for life during manufacture
and require no further lubrication unless the rubber
boot has been dislodged or damaged. All joints should
be checked at specified service intervals, but more
frequently if vehicle is used under arduous conditions.
1. Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent, fit a new joint assembly.
See
STEERING, Repair, Drop arm ball See
STEERING, Repair, Track rod and See
STEERING, Repair, Drag link and drag link
ends
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN AND CLEAN FUEL SEDIMENTER, IF
FITTED
The fuel sedimenter is located on a chassis side
member on the RH side of vehicle near rear wheel. It
increases the working life of the fuel filter by removing
larger droplets of water and other matter from fuel.
NOTE: On 110/130 models with a twin tank
fuel system, two sedimenters may be
fitted, one on each side of the vehicle
chassis.
1. Slacken drain plug and allow any water to drain
off.
10
MAINTENANCE
14
MAINTENANCE
2. When pure diesel is emitted, retighten drain
plug.
3. Disconnect fuel inlet pipe at sedimenter. Raise
and support pipe above level of fuel tank to
prevent fuel draining from tank.
4. Support sedimenter bowl, unscrew bolt and
remove bowl.
5. Remove sedimenter element.
6. Clean all components in kerosene.
7. Fit new seals.
8. Fit element into sedimenter bowl.
9. Secure bowl to sedimenter head.
10. Fit fuel inlet pipe to sedimenter.
11. Slacken drain plug and when pure diesel is
emitted, retighten plug.
12. If necessary, prime the system.
See FUEL SYSTEM, Adjustment, Priming
the fuel system
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK SECURITY OF TOWING BRACKET
FITTINGS
CARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests MUST
NOT be carried out.
For details of dynamometer testing.
See
INTRODUCTION, Information, Dynamometer
testing
Check the following components:
1. Engine for excessive noise.
2. Clutch for slip, judder or spin/drag.
3. Gear selection/noise - high/low range.
4. Steering for abnormal noise/effort.
5. Steering for free play.
6. All instruments, gauges and warning indicators.
7. Heater and air conditioning systems.
8. Heated rear screen.
9. Shock absorbers - ride irregularities.
10. Foot brake, on emergency stop, pulling to one
side, binding and pedal effort.
11. Handbrake operation.
12. Seat reclining and latching.
13. Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
14. Road wheel balance.
15. Transmissions for vibrations.
16. Body noises, squeaks and rattles.
17. Excessive exhaust smoke.
18. Engine idle speed.
19. Endorse service record.
20. Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD
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