Defender 300Tdi (1996+). Manual — part 39
MANUAL GEARBOX
1
REPAIR
R380 GEARBOX
Service repair no - 37.20.51
Remove
The R380 gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
support plate LRT-99-007.
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer’s instructions to ensure safe and
effective use of equipment.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray or
See CHASSIS AND BODY, Repair, Rear undertray
.
1. Install vehicle on a ramp.
2. Disconnect battery.
3. Remove gearbox carpet.
4. Remove gear lever and transfer box lever knobs.
5. Remove gear lever cover.
6. Remove nut and washer securing gear lever.
7. Mark gear lever spline setting and remove lever
and gaiter from the splined lower gear lever.
8. Release insulation pad from tunnel cover and
gear levers and remove.
9. Select low range on transfer box lever to prevent
lever from fouling tunnel when removing gearbox
37
MANUAL GEARBOX
2
REPAIR
10. Remove 3 trim studs and lift up handbrake
gaiter.
11. Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever. Ensure
handbrake is off.
12. Drain cooling system
See COOLING SYSTEM,
Adjustment, Drain and refill cooling system .
13. Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan .
14. Slacken retaining clip and disconnect radiator
top hose at thermostat housing.
15. Slacken retaining clip and disconnect intake
hose at induction manifold. If EGR system is
fitted, slacken 2 retaining clips and disconnect
intake hose at intercooler.
16. Slacken retaining clip and disconnect hose at
turbocharger.
17. Remove bolt securing transmission breather
pipe clip to rear of engine.
18. Release breather pipes.
19. Release ties securing gearbox harness to
breather pipes.
20. Raise vehicle on ramp.
21. Position a suitable container under transmission
and drain main gearbox and transfer box
See
SECTION 10, Maintenance, Under vehicle
maintenance .
22. Mark front propeller shaft drive flange and
transfer box output flange for reassembly.
23. Remove 4 nuts and disconnect propeller shaft
from transfer box.
MANUAL GEARBOX
3
REPAIR
24. Remove 2 bolts, withdraw clutch slave cylinder
and backing plate from bell housing, and tie
aside.
25. Mark rear propeller shaft drive flange and
transmission brake drum for reassembly.
26. Remove 4 nuts, disconnect propeller shaft from
brake drum, and tie aside.
27. Remove front pipe from exhaust manifold
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
Exhaust front pipe .
28. Remove intermediate silencer.
See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 90 or See MANIFOLD
AND EXHAUST SYSTEM, Repair,
Intermediate pipe - 110/130
29. Temporarily support transmission.
30. Remove nut securing gearbox LH mounting
rubber to chassis crossmember.
31. Remove 4 nuts and bolts securing crossmember
to chassis longitudinals.
32. Remove nut securing transfer box mounting
rubber to RH side of crossmember.
33. Remove 4 nuts and bolts securing crossmember
to chassis longitudinals.
34. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
35. Remove chasss crossmember.
36. Remove 4 bolts from both sides and remove LH
and RH mounting brackets.
37
MANUAL GEARBOX
4
REPAIR
37. Pull handbrake cable through heel board and tie
aside.
38. Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer box.
39. Release speedometer cable from retaining clip
on transfer box.
40. Remove retaining nut and release battery earth
strap from transfer box.
41. Secure manufactured cradle LRT-99-007 to a
suitable hydraulic hoist.
42. Raise hoist and secure to gearbox with 3 bolts in
location provided.
43. Lower hoist sufficiently to allow transfer lever to
clear transmission tunnel aperture.
44. Disconnect differential lock switch and reverse
light connectors.
45. Remove bolt and release earth leads from RH
side of transfer box.
46. Support engine under sump with a jack.
47. Remove 14 bell housing to engine fixings.
48. Withdraw transmission whilst ensuring all
connections to engine and chassis are released.
49. Lower hoist and remove gearbox assembly.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст