Defender 300Tdi (1996+). Manual — part 38
37
MANUAL GEARBOX
2
FAULT DIAGNOSIS
Symptom - Noise from gearbox in one or more
gears when being driven.
1. Check lubricant specification and level, if low do
not top up at this stage.
2. Drain lubricant and check for contamination or
metal particles.
Suspect worn roller bearings on particular
mainshaft gears, see Overhaul Manual.
MANUAL GEARBOX
1
ADJUSTMENT
GEAR CHANGE LEVER BIAS SPRING - ADJUST
Service repair no - 37.16.26
1. Remove gear lever and transfer box lever knobs.
2. Remove gear lever cover.
3. Remove nut and washer securing gear lever.
4. Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5. Remove insulation pad from tunnel aperture.
6. Fit gear lever and select 3rd or 4th gear.
7. Slacken adjustment screw locknuts.
8. Adjust screws until both legs of bias springs are
approximately 0.5mm clear of gear lever cross
pin.
9. Apply a slight load to gear lever in a LH direction
and adjust RH screw downward until RH spring
leg just makes contact with cross pin.
10. Repeat procedure for LH adjustment screw.
11. Lower both adjustment screws equal amounts
until radial play is eliminated.
12. Tighten locknuts.
13. Return gear lever to neutral position and rock
across gate several times. The gear lever should
return to 3rd and 4th gate.
14. Remove gear lever.
15. Fit insulation pad.
16. Locate gaiter over lower lever and bias springs.
17. Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
18. Fit gear lever cover.
19. Fit gear lever and transfer box lever knobs.
37
MANUAL GEARBOX
2
ADJUSTMENT
FIFTH GEAR STOP SCREW - ADJUST
Service repair no - 37.16.67
1. Remove gear lever and transfer box lever knobs.
2. Remove gear lever cover.
3. Remove nut and washer securing gear lever.
4. Mark gear lever spline setting, remove lever and
gaiter from lower lever.
5. Remove insulation pad from tunnel aperture.
6. Remove tunnel carpet.
7. Remove retaining screws and release fuse box
cover.
8. Remove 2 screws and release fuse box from
bulkhead to assist next operation.
9. Remove 16 screws securing tunnel cover to
vehicle body.
10. Manouvre tunnel cover to clear handbrake lever
and remove from vehicle.
11. Fit gear lever and knob and select reverse gear.
MANUAL GEARBOX
3
ADJUSTMENT
12. Slacken stop screw locknut.
13. Apply light pressure to gear lever towards LH
side and turn screw clockwise until it abuts yoke.
14. Turn screw anti-clockwise until 25 mm freeplay
is felt at gear lever knob. Ensure 5th gear can be
engaged.
15. Tighten stop screw locknut.
16. Check that all other gears are selectable.
17. Remove gear lever.
18. Manouvre tunnel cover into position and secure
with 16 screws.
19. Fit fuse box and cover.
20. Fit tunnel carpet.
21. Fit insulation pad into tunnel aperture.
22. Locate gaiter over lower lever and bias springs.
23. Fit gear lever to lower lever spline, secure with
new nyloc nut and tighten to
25 Nm (18 lbf/ft).
24. Fit gear lever cover.
25. Fit gear lever and transfer box lever knobs.
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