Defender. Manual — part 180
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the intermediate gears
the centre differential assembly
The front and rear output housings are bolted to either side of the main casing.
Mainshaft Input Gear
The transmission output shaft is splined into the mainshaft input gear, which is supported by taper roller bearings.
Input gear bearing pre-load is achieved by the use of a selective shim located in the bearing housing.
Intermediate Gears
The intermediate gear cluster is supported by the taper roller bearings located at each end of the cluster and runs on
the intermediate shaft, which in turn, is supported at the front and rear by the main casing.
Intermediate gear bearing pre-load is achieved by means of a collapsible spacer positioned between the bearings, the
amount of compression applied to the spacer is by means of a nut on the end of the intermediate shaft.
The bore of the intermediate gear is machined with a shoulder at each end to locate the bearings.
Centre Differential Assembly
Item
Part Number
Description
1
-
Retaining ring
2
-
Differential carrier - rear half
3
-
Low range gear
4
-
High/low hub
5
-
High/low selector sleeve
6
-
High/low selector shaft
7
-
High/low selector fork
8
-
Setscrew - high/low selector fork
9
-
High range gear
10
-
High range gear bush
11
-
Differential rear bearing
12
-
Bearing outer track
13
-
Bearing retaining nut
14
-
Dished thrust washers
15
-
Differential planet gears
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16
-
Cross shafts
17
-
Differential side gears
18
-
Selective thrust washers
19
-
Differential carrier - front half
20
-
Bolt - differential carriers
21
-
Differential front bearing
22
-
Bearing outer track
23
-
Selective shim
The centre differential assembly is supported at the front and rear by taper roller bearings, the front bearing outer track
is located in the front output housing and the rear bearing outer track is located in the main casing by the rear output
housing. Bearing pre-load is achieved by means of a selective shim located in the front output housing.
The centre differential rear shaft carries the low range gear, high/low selector sleeve and hub, high range gear and bush
and the differential rear bearing; these components being secured to the shaft by a special staked nut.
The assembly comprises front and rear half carriers with integral shafts connected to differential side gears and planet
gears mounted on cross shafts within the half carriers. Dished, non-selective thrust washers control the engagement of
the planet gears with the differential side gears, whilst selective thrust washers are used to control engagement of the
differential side gears and 'torque to turn' of the differential. The differential carrier halves are bolted together, a
retaining ring providing positive location of the cross shafts.
The high/low selector shaft and fork are located at the side of the differential, movement of the shaft, fork and selector
sleeve being controlled by the high/low selector finger. A spring loaded detent ball fitted in the main casing, locates in
grooves in the shaft.
The selector fork is fitted with a spring assister and clips to reduce the effort required to move the selector lever.
FRONT OUTPUT HOUSING
Item
Part Number
Description
1
-
Hollow plug
2
-
High/low cross shaft housing
3
-
Bolt - high/low cross shaft housing
4
-
O-ring
5
-
High/low cross shaft and lever with cable ball end
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6
-
Dog clutch
7
-
Front output shaft
8
-
Differential lock selector shaft
9
-
Front output housing
10
-
Spring and clips - differential lock
11
-
Bolt - Cover plate
12
-
Cover plate
13
-
Differential lock selector fork
14
-
Detent plug and spring - differential lock
15
-
Detent ball - differential lock
16
-
Bolt - front output housing
17
-
Plug
18
-
Circlip
19
-
Output shaft flange and mud shield
20
-
Steel washer
21
-
Self-locking nut
22
-
Felt washer
23
-
Oil seal
24
-
Output shaft bearing
25
-
Bearing spacer
26
-
High/low selector finger
27
-
Differential lock warning indicator switch
28
-
Differential lock selector finger and shaft
29
-
O-rings
30
-
Differential lock selector housing
31
-
Selector lever
32
-
Bolt - housing
33
-
Washer
34
-
Self-locking nut
The front output housing carries:
the front output shaft and flange
the housing and selector
the differential lock selector shaft and fork
Front Output Shaft and Flange
The front output shaft is supported in the housing by a single bearing and is splined into the differential front sun gear.
Housing and Selector Assembly
A high/low cross shaft is located in a housing bolted to the top of the output housing and is connected to the high/low
selector finger, which locates in a slot in the selector shaft.
Differential Lock Selector Shaft and Fork
The differential lock selector housing is bolted to the top of the front output housing, the selector finger passes through
the housing, locating in a slot in the differential lock selector shaft. The differential lock selector shaft passes through
the selector fork, which is located beneath a plate bolted to the side of the output housing. The selector fork engages
the dog clutch sleeve with the differential rear shaft when the splines of the sleeve and differential rear shaft are
aligned. A spring loaded detent ball fitted in the output housing locates in grooves in the shaft.
REAR OUTPUT HOUSING
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Item
Part Number
Description
1
-
Rear output shaft
2
-
Rear output housing
3
-
Bolt - rear output housing
4
-
Speedometer drive gear
5
-
Spacer
6
-
Output shaft bearing
7
-
Circlip
8
-
Oil seal
9
-
Mud shield
10
-
Output shaft flange
11
-
Felt washer
12
-
Steel washer
13
-
Self-locking nut
14
-
Transmission brake backplate
15
-
Bolt - transmission brake backplate
16
-
Transmission brake drum
17
-
Countersunk screw
18
-
Speedometer driven gear
19
-
O-ring
20
-
Speedometer driven gear housing
21
-
Seal
22
-
O-ring
23
-
Vehicle speed sensor (if fitted)
24
-
Allen screw (if fitted)
The rear output housing carries the output shaft and flange and the speedometer drive and driven gears. A
mechanically operated transmission brake is attached to the housing, the brake drum being attached to the output
flange.
The rear output shaft is supported in the rear output housing by a single bearing and is splined into the differential rear
shaft. The output shaft also carries the speedometer drive gear, which meshes with the speedometer driven gear
located in the rear output housing.
A differential lock warning lamp switch operated by movement of the selector fork and shaft is screwed into the top of
the output housing.
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