Defender. Manual — part 178
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Manual Transmission/Transaxle External Controls - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma - Gearshift Lever
Removal and Installation
Removal
1. Remove the transfer case high/low range linkage.
For additional information, refer to:
Transfer Case High/Low
Range Linkage
(308-07A Transfer Case - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, In-vehicle Repair).
2. Remove and discard the differential lock pivot nut.
3. NOTE: Do not remove the 4 gearshift lever ball joint
securing screws.
• NOTE: Make sure the rubber seal is not damaged on
removal.
Remove the gearshift lever.
Remove the 4 bolts.
Installation
1. NOTE: Make sure the gearshift selector lever ball joint bush
and the selector yoke are centralised before installing the
special tool.
• NOTE: Make sure the rubber gasket is fitted to the gearshift
lever housing before installation.
Install the gearshift lever.
Make sure 3rd gear is engaged on the transmission.
Install the gearshift lever.
Install the special tool onto the gearshift lever.
2. Tighten the bolts to 25 Nm (18 lb.ft).
![](/vehicles/onond/qug/lecmbuttig/creve.png)
2. Tighten the bolts to 25 Nm (18 lb.ft).
3. Remove the special tool.
4. Install a new differential lock pivot nut.
Tighten the nut to 25 Nm (18 lb.ft).
5. Install the transfer case high/low range linkage.
For additional information, refer to:
Transfer Case High/Low
Range Linkage
(308-07A Transfer Case - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, In-vehicle Repair).
![](/vehicles/onond/qug/lecmbuttig/nghave.png)
Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Lubricants
Item
Specification
Recommended oil
API GL4 or GL5, MIL-L-2105 or MIL-L-2105B
Capacity
2.3 litres, (4.0 pints)
CAUTION: Do not use any lubricant other than that specified
General Specification - LT230Q
Item
Specification
Transfer case
type
LT230QRS
Specification
Two speed reduction on main gearbox output, front and rear drive permanently engaged via a lockable
differential
Ratios:
High
1.211:1
Low
3.269:1
Transfer case data
Item
Metric
Imperial
High/low selector finger width
15.90 to 15.95 mm
0.625 to 0.627 in
High/low selector fork finger width
7.37 to 7.47 mm
0.290 to 0.294 in
High/low selector shaft groove width
16.0 to 16.1 mm
0.63 to 0.64 in
High/low selector hub groove width
7.5 to 7.6 mm
0.295 to 0.30 in
Differential lock selector finger width
15.90 to 15.95 mm
0.625 to 0.627 in
Differential lock selector shaft groove width
16.0 to 16.1 mm
0.63 to 0.64 in
Differential lock selector fork finger width
7.92 to 7.9 mm
0.311 to 0.313 in
Differential lock selector spring free length
84.58 mm
3.33 in
Dog clutch selector fork groove width
8.05 to 8.20 mm
0.32 to 0.33 in
Differential front and rear half carrier gears load to turn:
Used gears
0.45 kg
1.0 lb
New gears
1.72 kg
3.8 lb
Thrust washer thicknesses available
1.05 to 1.45 mm
0.04 to 0.06 in
In increments of:
0.10 mm
0.004 in
Total load to turn - both sun gears fitted:
Used gears
0.90 kg
2.0 lb
New gears
3.44 kg
7.6 lb
Low range gear to high range hub clearance
0.05 to 0.15 mm
0.002 to 0.006 in
High range gear to high/low hub clearance
0.05 to 0.10 mm
0.002 to 0.004 in
Mainshaft input gear bearing pre-load
0.05 mm
0.002 in
Mainshaft input gear bearing shim thicknesses
3.15 to 4.00 mm
0.12 to 0.16 in
In increments of:
0.05 mm
0.002 in
Differential bearing pre-load
0.05 mm
0.002 in
Differential shim thicknesses available
In increments of
0.05 mm
0.002 in
Transfer case gear train torque to turn
3.4 Nm max
30 lbf.in max
Torque Specifications
Description
Nm
lb-ft
Drain plug
30
22
Transfer case breather banjo
15
11
Differential carrier bolts
60
44
Differential bearing nut
72
53
Differential lock selector lever nut
25
18
* Front output housing bolts
25
18
* Rear output housing bolts
45
33
*** Output flange nuts
162 120
* Differential lock selector housing bolts
25
18
High/low selector housing bolts
25
18
* Intermediate shaft retaining plate bolt
25
18
*** Intermediate shaft stake nut - Selective length non-collapsible spacer
88
65
* Bottom cover bolts
25
18
* Bearing housing cover plate bolts and stud nut
25
18
Transmission brake backplate bolts
72
54
Interlock solenoid cover bolts - if fitted
10
8
** Neutral warning lamp switch
25
18
Transfer case front drive flange to drive shaft
47
33
![](/vehicles/onond/qug/lecmbuttig/hil.png)
Transfer case rear drive flange to drive shaft
50
37
Transfer case to gearbox extension case
47
33
* Apply Loctite 290 to threads
** Apply Hylomar PL32 to threads
*** New nut must be fitted
Item
Nm
lbf-ft
METRIC
M5
6
5
M6
9
7
M8
25
18
M10
45
33
M12
90
65
M14
105
75
M16
180
130
UNF/UNC
1/4
9
7
5/16
25
18
3/8
40
30
7/16
80
60
!
90
65
5/8
135
100
The table above provided torque values for screws and bolts not previously specified.
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