Defender 300Tdi (1996+). Manual — part 42
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TRANSFER GEARBOX
3
REPAIR
23. Position 4, 30 mm (1.25 in), spacers between
top of hoist and adaptor plate, LRT-99-010, at
securing points and secure adaptor plate to
hoist.
24. Remove 4 central bolts from transfer box bottom
cover, move hoist into position and secure
adaptor plate to transfer box.
25. Adjust hoist to take weight of transfer box.
26. Remove nut securing transfer box LH mounting
rubber to chassis crossmember.
27. Remove 4 nuts and bolts securing chassis
crossmember to chassis longitudinal.
28. Remove nut securing transfer box RH mounting
rubber to chassis crossmember.
29. Remove 4 nuts and bolts securing chassis
crossmember to chassis longitudinal.
30. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
31. Remove chassis crossmember.
32. Remove 4 bolts from both sides and remove LH
and RH mounting brackets from transfer box.
33. Disconnect electrical leads from differential lock
switch.
34. Move the small cranked lever, for high/low
selector, upward to allow access to adjacent nut
securing transfer box to main gearbox.
35. Position a jack to support main gearbox.
CAUTION: Use a block of wood or hard
rubber pad to protect gearbox.
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41
TRANSFER GEARBOX
4
REPAIR
36. Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer
gearbox.
37. Remove battery earth strap retaining nut, 1 nut
and 4 bolts, securing transfer box to main
gearbox extension case.
38. Remove retaining nut securing earth leads to RH
side of transfer box.
39. Fit three guide studs, LRT-41-009, through
transfer box bolt holes to support it during
removal.
40. Lower hoist and withdraw transfer box from main
gearbox.
41. Remove transfer box.
Refit
42. Ensure joint faces of transfer box and main
gearbox are clean and guide studs, LRT-41-009,
are fitted to extension case.
43. Lubricate oil seal in joint face of transfer box.
44. Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
45. Remove guide studs, fit battery earth strap, and
secure transfer box to main gearbox extension
case. Tighten fixings to
45 Nm (33 lbf/ft).
46. Fit electrical leads to differential lock switch.
47. Raise hoist and remove wooden block
supporting main gearbox.
48. Secure LH and RH mounting brackets to
gearbox and tighten fixings to
55 Nm (41 lbf/ft).
49. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
50. Position chassis crossmember and locate over
fixing studs of LH and RH gearbox mounting
rubbers .
51. Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
52. Remove body jack.
53. Fit retaining nut to LH and RH mounting rubbers.
Tighten to
21 Nm (15 lbf/ft).
54. Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
55. Lower hoist and move aside.
56. Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to
25 Nm (18 lbf/ft).
57. Fit earth leads to RH side of transfer box.
58. Connect differential lock control operating rod to
pivot arm.
59. Fit speedometer cable to transfer box.
60. Fit front and rear propeller shafts to transfer box.
Tighten nuts to
47 Nm (33 lbf/ft).
61. Fit intermediate silencer.
See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
silencer - 90; Refit or See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 110/130; Refit .
62. Refill transfer box with recommended oil
See
SECTION 10, Maintenance, Under vehicle
maintenance
TRANSFER GEARBOX
5
REPAIR
63. Feed transmission brake cable through heel
board. Ensure cable grommet is correctly
located.
NOTE: Apply a soap solution to aid fitment
of cable.
64. Lower vehicle ramp.
65. Connect cable clevis to handbrake lever and fit
handbrake gaiter.
66. Connect high/low lever to operating rod.
67. Fit breather pipe banjo union to high/low
cross-shaft housing.
68. Fit cntre access panel to seat base. If fitted,
secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.
69. If fitted, reconnect multi-plug to EGR control unit
on base of centre seat cushion or cubby box.
70. Fit seat cushion or cubby box
See CHASSIS
AND BODY, Repair, Cubby box .
71. Reconnect battery.
72. Check operation of handbrake and adjust as
necessary
See BRAKES, Repair, Handbrake
cable .
TRANSFER 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
Transfer gearbox
Pinch bolt - operating arm to crank arm
9
. . . . . . . . . . . . . ..
End cover gear change housing
9
. . . . . . . . . . . . . . . . .
Bottom cover to transfer case
25
. . . . . . . . . . . . . . . . .
Front output housing to transfer case
25
. . . . . . . . . . . . . .
Cross shaft housing to front output housing
25
. . . . . . . . . . . ...
Gear change housing
25
. . . . . . . . . . . . . . . . . . . . .
Pivot shaft to link arm
25
. . . . . . . . . . . . . . . . . . . . .
Connecting rod to adjustable clevis
25
. . . . . . . . . . . . . . ...
Anti-rotation plate intermediate shaft
25
. . . . . . . . . . . . . . .
Front output housing cover
25
. . . . . . . . . . . . . . . . . .
Pivot bracket to extension housing
25
. . . . . . . . . . . . . . .
Finger housing to front output housing
25
. . . . . . . . . . . . . ..
Bearing housing to transfer case
25
. . . . . . . . . . . . . . . ...
Brake drum to coupling flange
25
. . . . . . . . . . . . . . . . ...
Bearing housing cover to transfer gearbox
45
. . . . . . . . . . . .
Rear output speedometer housing to transfer gearbox
45
. . . . . . . ..
Selector finger to cross shaft high/low
25
. . . . . . . . . . . . . ...
Selector fork, high/low to shaft
25
. . . . . . . . . . . . . . . . ...
Transmission brake to speedometer housing
72
. . . . . . . . . . .
Gate plate to grommet plate
9
. . . . . . . . . . . . . . . . . ...
Gearbox to transfer case
45
. . . . . . . . . . . . . . . . . . ...
Oil drain plug
30
. . . . . . . . . . . . . . . . . . . . . . . ..
Oil filler/level plug
30
. . . . . . . . . . . . . . . . . . . . . ...
Differential case (front to rear)
60
. . . . . . . . . . . . . . . . ...
Output flanges
162
. . . . . . . . . . . . . . . . . . . . . . ...
Differential case rear stake nut
72
. . . . . . . . . . . . . . . . ..
Transfer breather
15
. . . . . . . . . . . . . . . . . . . . . ...
Transfer box front drive flange to drive shaft
45
. . . . . . . . . . . ..
Transfer box rear drive flange to drive shaft
45
. . . . . . . . . . . ..
Transfer gearbox mounting brackets to chassis
30
. . . . . . . . . .
Mounting brackets to transfer gearbox
55
. . . . . . . . . . . . . ..
Mounting rubbers to mounting brackets
21
. . . . . . . . . . . . . .
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