Range Rover Classic. Manual — part 68
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23. Fit the snap ring with the stepped ends adjacent
to the selector shaft bore.
24. Turn the rear cover over and fit the circlip to
retain the sun gear shaft.
25. Remove any previous sealant from the end cap.
Apply Dow Corning 732 silicon sealant or a
suitable equivalent to the outside diameter of the
rear cover, evenly tap the cap into position.
26. If necessary re - position the filter on the oil pick
- up pipe until the lug on the filter can be pushed
into the slot in the rear cover.
Selector fork
- Dismantle and inspection
1. Remove the retaining clip and separate the fork
from the arm.
2. Detach the two nylon slippers from the selector
fork feet and discard.
3. Thoroughly clean all components.
4. Examine the fork, arm and pivot pin for wear.
Renew as necessary.
5. Remove the ’O’ ring and discard. Examine the
shaft and lever for wear and damage, renew as
necessary.
6. Examine the selector sleeve teeth and internal
splines for damage and wear. Renew as
necessary.
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Selector fork - Assemble
7. Fit new nylon slippers to the fork.
8. Assemble the fork to the selector arm and
secure in position using a new retaining clip.
9. Lightly lubricate and fit the spring and selector
plunger.
10. While compressing the plunger and spring, fit the
selector fork, operating arm assembly and
selector sleeve simultaneously.
11. Select neutral gear position at the operating arm.
12. Fit a new ’O’ ring to the selector lever shaft.
Lubricate the ’O’ ring and fit the lever assembly
to the rear cover, noting that when fully
assembled the lever should lie parallel with the
joint face of the rear cover.
13. Fit a new retaining clip to secure the selector
fork operating arm to the selector lever shaft.
14. Remove any previous sealant from the Torx
screw. Align the selector lever shaft groove to
the retaining screw hole, apply a small amount of
Loctite 242 to the screw threads and using Torx
bit 25 fit and tighten the screw to the specified
torque. Ensure that the screw locates in the
groove of the shaft.
15. Clean any previous sealant from the Torx screw.
Apply a small amount of Loctite 242 to the
threads of the screw and fit to the selector fork
operating arm, tighten using Torx bit 25 to the
specified torque.
Bearing carrier
- Dismantle, inspection and assemble
1. Remove the circlip and drive or press the
transfer shaft from the bearing.
2. Remove the circlip retaining the bearing in the
carrier.
3. Drive or press the bearing from the carrier and
discard the bearing.
4. Clean and examine the carrier for cracks and
general condition. Renew as necessary.
5. Press or drive a new bearing into the carrier and
secure with the circlip.
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Transfer shaft
- Inspection and assemble
1. Clean the transfer shaft.
2. Visually examine the external splines for
damage and wear, if worn fit a new component.
3. Check the phospher bronze bush for wear by
measuring the internal diameter of the bush with
internal calipers and a micrometer or with an
internal micrometer. The bush diameter must not
exceed 38.515 mm (1.516 in) fit a new transfer
shaft if the bush has worn above the figure
given.
4. Drive or press the transfer shaft into the bearing
in the carrier. Secure the shaft with the circlip.
5. Fit the carrier to the rear cover, fit the anti -
rotation dowel and secure the assembly with the
snap ring, noting that the open ends of the snap
ring must be positioned by the cast relief in the
bearing carrier upper face.
Transfer sprocket - Inspection
1. Examine the sprocket teeth and splines for wear
and damage, if either are evident discard the
sprocket, otherwise clean and place to one side.
Chain - Inspection
NOTE: A stretched chain can be identified
by either excessive noise when the
gearbox is operational or by witness
marks on the inside edges of the case. If either is
evident, renew the chain.
1. Using a suitable solvent thoroughly clean the
chain.
2. Check the chain links for wear and damage, if
necessary renew the chain.
3. Place the chain to one side.
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Centre differential and sprocket
- Dismantle and inspection
1. Place the differential unit in a vice fitted with soft
jaws. If the original components are to be refitted
mark an identification line on the sprocket and
differential unit.
2. Remove the bolts securing the sprocket to the
differential.
3. Lift the differential assembly from the sprocket.
4. Examine the sprocket teeth for wear and
damage, if either are evident renew the sprocket.
Place the sprocket aside until the differential is
ready to be assembled.
Centre differential
- Dismantle and inspection
1. Using a two legged puller, ease the bearings
from the differential assembly and discard the
bearings.
2. Secure the front half of the differential unit in a
vice fitted with soft jaws, remove the eight
retaining bolts securing the front and rear halves
of the assembly together, lift off the rear part of
the differential unit. Note the identification marks
on the exterior of the differential unit.
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