Defender 300Tdi (1996+). Manual — part 40
MANUAL GEARBOX
5
REPAIR
Separating transfer gearbox from main gearbox
50. Remove transmission assembly from hoist
cradle and position safely on a bench.
51. Remove breather pipes. Discard pipe union
sealing washers.
52. Remove ’Nyloc’ nut, and remove bolt, securing
lever to high/low shaft.
53. Collect spacer washer.
54. Remove 2 clips and remove differential lock
lever link.
55. Remove lower locknut from high/low operating
rod.
56. Place a sling round transfer box and attach to
hoist.
57. Remove nut and 4 bolts securing transfer
gearbox to extension housing.
58. Withdraw transfer gearbox.
Assembling transfer gearbox to main gearbox
59. Clean extension housing and transfer gearbox
mating faces.
60. Ensuring loose upper dowel is fitted, hoist
transfer gearbox into position.
61. Secure transfer box to extension housing.
Tighten fixings to
40 Nm (30 lbf/ft).
62. Connect high/low operating rod, fit and tighten
locknut.
63. Fit link to differential lock lever and secure with 2
clips
64. Align lever to high/low shaft, position washer, fit
bolt and new Nyloc nut. Tighten to
2 Nm (1.5
lbf/ft).
65. Position breather pipes, secure pipe unions
using new sealing washers. Tighten unions to
15
Nm (11 lbf/ft).
Fitting transfer gearbox and main gearbox
assembly
66. Position transmission assembly to hoist cradle.
67. Clean bell housing and engine mating faces.
Apply sealant to both mating faces.
68. Temporarily fit gear lever and select any gear in
main gearbox to facilitate entry of gearbox input
shaft. Engage low range.
69. Position and raise hoist, fit transmission to
engine whilst keeping harness and pipes clear to
prevent trapping.
70. Secure transmission to engine. Tighten fixings to
45 Nm (33 lbf/ft).
71. Secure earth leads to RH side of transfer box.
72. Connect reverse lamp switch connectors and
differential lock switch connectors.
73. Secure breather pipes to harness with clips.
74. Remove support from engine sump.
75. Position temporary support under transmission.
76. Secure LH and RH mounting brackets to
gearbox. Tighten fixings to
55 Nm (41 lbf/ft).
77. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
37
MANUAL GEARBOX
6
REPAIR
78. Position crossmember and locate over fixing
studs of LH and RH gearbox mounting rubbers.
79. Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaing clip
to LH top bolt.
80. Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 90 or See MANIFOLD AND EXHAUST
SYSTEM, Repair, Intermediate pipe - 110/130
.
81. Fit front pipe to exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe .
82. Fit rear propeller shaft to transmission brake
drum. Tighten nuts to
47 Nm (33 lbf/ft).
83. Remove 3 bolts securing support cradle to
transmission and remove hoist.
84. Reconnect battery earth strap to transfer box
fixing.
85. Connect speedometer cable to transfer box and
secure with retaining clip.
86. Coat both sides of clutch slave clinder backing
plate with Hylomar P232M waterproof sealant.
87. Locate backing plate on slave cylinder.
88. Fit slave cylinder to bell housing, engaging
push-rod through centre of dust cover, and with
bleed screw uppermost. Tighten bolts to
25 Nm
(18 lbf/ft).
89. Fit front propeller shaft to transfer box. Tighten
nuts to
47 Nm (33 lbf/ft).
90. Refill main gearbox and transfer box
See
SECTION 10, Maintenance, Under vehicle
maintenance .
91. Feed transmission brake cable through heel
board and ensure grommet is correctly located.
NOTE: Apply a soap solution to aid fitment
of cable.
92. Lower vehicle on ramp.
93. Fit ties to secure gearbox harness to
transmission breather pipes.
94. Fit breather pipe retaining clip to rear of engine.
95. Reconnect charge air hose at turbocharger.
96. Reconnect intake hose at induction manifold. If
EGR system is fitted, reconnect intake hose at
intercooler.
97. Reconnect radiator top hose at thermostat
housing.
98. Fit viscous fan unit
See COOLING SYSTEM,
Repair, Viscous coupling and fan .
99. Reconnect battery.
100. Refill cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system .
101. Connect cable clevis to handbrake lever and fit
handbrake gaiter.
102. Locate insulation pad over gear levers and fit to
tunnel cover.
103. Fit gear lever with gaiter to lower lever spline
and secure with retaining nut.
104. Fit gear lever cover.
105. Fit gear lever and transfer box lever knobs.
106. Fit gearbox cover carpet.
107. Check operation of handbrake and adjust as
necessary
See SECTION 10, Maintenance,
Under vehicle maintenance .
MANUAL GEARBOX
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Slave cylinder to bell housing
25
. . . . . . . . . . . . . . . . .
Breather
15
. . . . . . . . . . . . . . . . . . . . . . . . . .
Bell housing to cylinder block
40
. . . . . . . . . . . . . . . . . .
High/low level to shaft
2
. . . . . . . . . . . . . . . . . . . . .
Transfer box to gearbox
45
. . . . . . . . . . . . . . . . . . . .
NOTE: Torque values below apply to all screws and bolts used unless otherwise specified.
METRIC
Nm
M5
6
. . . . . . . . . . . . . . . . . . . . . . . . . ..
M6
9
. . . . . . . . . . . . . . . . . . . . . . . . . ..
M8
25
. . . . . . . . . . . . . . . . . . . . . . . . . .
M10
45
. . . . . . . . . . . . . . . . . . . . . . . . ...
M12
90
. . . . . . . . . . . . . . . . . . . . . . . . ...
M14
105
. . . . . . . . . . . . . . . . . . . . . . . . ..
M16
180
. . . . . . . . . . . . . . . . . . . . . . . . ..
UNC / UNF
1/4
9
. . . . . . . . . . . . . . . . . . . . . . . . . ..
5/16
24
. . . . . . . . . . . . . . . . . . . . . . . . ...
3/8
39
. . . . . . . . . . . . . . . . . . . . . . . . . .
7/16
78
. . . . . . . . . . . . . . . . . . . . . . . . ...
1/2
90
. . . . . . . . . . . . . . . . . . . . . . . . . .
5/8
136
. . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER GEARBOX
1
DESCRIPTION AND OPERATION
TRANSFER GEARBOX
Description
The transfer gearbox is a permanent 4 wheel drive,
two speed ratio reducing gearbox, incorporating high
and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
The transfer gearbox is mounted at the rear of the
main gearbox, the mainshaft of which extends into the
transfer casing. A transfer gear, supported on taper
roller bearings and splined to the gearbox mainshaft,
passes the drive to an intermediate gear cluster
supported on a single shaft and rotating on taper roller
bearings.
The intermediate gears pass the drive to high and low
speed gears on the rear output shaft. The rear output
shaft passes through the speedo drive housing, which
also forms the mounting for the transmission brake. A
worm gear fitted to the rear output shaft drives a
pinion fitted in the speedo housing.
Integral with the output shafts is a differential
assembly which compensates for speed differences
between the front and rear prop shafts. To prevent all
the power being transmitted to the axle offering the
least resistance, a diff-lock is provided. The differential
lock should only be engaged during severe off-road
conditions and should be disengaged as soon as
conditions permit. Selection of differential lock
engages, through mechanical linkage, a dog clutch
with the front output shaft, this action locks the centre
differential and provides a fixed drive, giving equal
power to the front and rear output shafts.
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