Defender. Manual — part 175
7. NOTE: Apply sealant STC 50552 to the bolt threads.
With assistance, install the transfer case.
Tighten the bolts to 45 Nm (33 lb.ft).
Tighten the nuts to 45 Nm (33 lb.ft).
8. NOTE: This step must be carried out if a new transmission is
being fitted.
Install the gear selector housing securing bolts to cut a new
thread.
Remove the bolts.
9.
CAUTION: Care must be taken when locating the
transmission to the clutch.
Install the transmission and transfer gearbox.
10. NOTE: Make sure the rubber gasket is fitted to the
gearshift lever housing before installation.
Install the gear selector housing.
11. NOTE: From below the vehicle.
Install the 3 accessible gear selector housing securing bolts
by hand only.
12. Position the transmission to the engine.
13. Install the bell housing bolts.
Tighten to 40 Nm
14. Install the RH transfer gearbox mounting bracket.
Tighten the nut to 48 Nm
Tighten the bolts to 85 Nm
15. Install the LH transmission mount and mounting bracket.
Tighten the nut to 48 Nm
Tighten the bolts to 85 Nm
16. Remove the special tool HTJ1200-02 from the transmission
16. Remove the special tool HTJ1200-02 from the transmission
and transfer gearbox.
17. Connect the clutch slave cylinder fluid hose to the clutch
slave cylinder.
Remove the blanking plugs from the orifices.
Install a new clutch slave cylinder fluid hose O-ring seal.
Install the clutch slave cylinder line clip.
18. Install and fully tighten the clutch slave cylinder fluid
hose mounting bracket securing nut and bolt.
Remove the pipe clamp from the clutch slave cylinder
fluid hose.
Tighten the bolt to 25 Nm
19. Secure the wiring harness to the transmission.
20. Reposition the transmission harness and install the
20. Reposition the transmission harness and install the
transmission harness retaining bracket securing nut and
bolt.
Tighten to 47 Nm
21. Install the transfer gearbox breather pipe.
Install new sealing washers onto the transfer gearbox
breather pipe securing bolt.
Install the securing bolt.
Tighten to 15 Nm.
22. Connect the differential lock detection switch electrical
connector.
Secure the electrical connector to the bracket.
23. Reposition and secure the high-low detection switch
electrical connector onto the transfer gearbox.
Secure the electrical connector to the bracket.
24. Install the RH transfer gearbox earth cables securing bolt.
Tighten to 12 Nm
25. Install the LH transfer gearbox earth cable securing nut.
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