Defender. Manual — part 158
Item
Part Number
Description
1
-
Retaining bolt
2
-
Ball bearing, layshaft
3
-
Retaining plate - bearing
4
-
Input pinion, layshaft
5
-
Gear - 6th gear
6
-
Gear wheel - 3rd gear
7
-
3rd gear synchroniser cone
8
-
Inner synchroniser ring
9
-
Outer synchroniser ring - 3rd gear
10
-
Needle bearing
11
-
Snap ring
12
-
3rd/4th gear synchroniser assembly
13
-
Outer synchroniser ring - 4th gear
14
-
Inner synchroniser ring
15
-
4th gear synchroniser cone
16
-
Gear wheel - 4th gear
17
-
Needle bearing
18
-
Centre bearing, layshaft
19
-
Layshaft
20
-
Roller bearing, layshaft
21
-
Reverse gear idler
The layshaft transfers the torque from the input shaft onto the output shaft. Gear wheels and gears and the 3rd/4th
gear synchroniser assembly are located on the shaft. First, 2nd and reverse gears are an integral part of the shaft.
The layshaft gearwheels and gears can be replaced individually. Because of improved manufacturing tolerances, it is no
longer necessary to change the gears and gear wheels in pairs.
The layshaft is a solid shaft. In order to prevent the shaft from moving axially, it is additionally secured with a retaining
bolt (1) and a bearing retaining plate (3).
The rotational direction of the output shaft is reversed by the use of the reverse gear idler (21).
OUTPUT SHAFT
Item
Part Number
Description
1
-
Snap ring
2
-
5th/6th gear synchroniser assembly
3
-
6th gear synchroniser ring
4
-
Splined synchroniser, 6th gear
5
-
Gear wheel - 6th gear
6
-
Needle bearing
7
-
Output shaft
8
-
Centre bearing - output shaft
9
-
Needle bearing
10
-
Gear wheel - 2nd gear
11
-
2nd gear synchroniser cone
12
-
Inner synchroniser ring
13
-
Outer synchroniser ring - 2nd gear
14
-
Snap ring
15
-
Ball bearing, output shaft
16
-
Retaining plate - bearing
17
-
Reverse gear synchroniser assembly
18
-
Reverse gear synchroniser ring
19
-
Gear wheel - reverse gear
20
-
Needle bearing
21
-
Inner race - needle bearing
22
-
Needle bearing
23
-
Gear wheel - 1st gear
24
-
1st gear synchroniser cone
25
-
Inner synchroniser ring - 1st gear
26
-
Outer synchroniser ring - 1st gear
27
-
1st/2nd gear synchroniser assembly
The output shaft transfers torque through the output flange, to an extension shaft connected to the transfer box. 1st,
2nd, 6th and reverse gear wheels are located on the output shaft. 3rd and 4th gears are an integral part of the output
shaft.
In a similar way to the input shaft, there is a splined synchroniser (4) pushed on the 6th gear gear wheel. This makes it
possible to transfer the torque in 6th gear.
The output shaft gearwheels and gears can be replaced individually.
TRIPLE SYNCHRONISER ASSEMBLY
Item
Part Number
Description
1
-
1st/2nd gear synchroniser assembly
2
-
Outer synchroniser ring
3
-
Inner synchroniser ring
4
-
Synchroniser cone
5
-
Gear wheel
6
-
Conical surface
The Synchronisation assembly consists of 3 friction surfaces. The total friction surface of triple synchronisation is
considerably increased by the additional conical surface (6). This leads to a reduction in the force needed to change into
1st or 2nd gear.
As the conical surface is part of the gear wheel, there is no need for an additional synchroniser ring.
SYNCHRONISER ASSEMBLY
Item
Part Number
Description
1
-
Sliding block assembly
2
-
Synchroniser hub
3
-
Sliding collar
The pressure springs and detent balls of the sliding blocks are combined in one unit.
REVERSE GEAR IDLER
Item
Part Number
Description
1
-
Mounting
2
-
Reverse gear idler shaft
3
-
Needle bearing
4
-
Reverse gear idler
5
-
Retaining bolt - reverse gear mounting
The reverse gear idler allows the direction of rotation of the output shaft to be reversed. The reverse gear idler turns on
a needle bearing, which runs on the reverse gear idler shaft. The shaft is retained by the mounting (1) and a locating
bore in the transmission housing.
In order to absorb the radial forces, the reverse gear idler runs on an additional mounting.
If the reverse gear idler can be replaced as an individual unit.
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