Defender (1999-2002). Manual — part 83
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TRANSFER GEARBOX
11
REPAIR
3. Remove screw securing brake drum.
4. Remove brake drum.
5. Restrain transfer gearbox drive flange using
LRT-51-003 , remove and discard drive flange
nut, remove and discard steel and felt washers.
6. Using LRT-99-500 if necessary, remove drive
flange from transfer gearbox.
7. Remove and discard rear output shaft oil seal
from transfer gearbox.
Refit
8. Clean seal recess.
9. Lubricate new oil seal with transfer gearbox oil.
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41
TRANSFER GEARBOX
12
REPAIR
10. Fit new seal using LRT-41-012 .
NOTE: Use end of tool marked ’REAR’ to
fit seal.
11. Position drive flange, fit new felt and steel
washers.
12. Position LRT-51-003 fit and tighten new drive
flange nut to 148 Nm (109 lbf.ft).
13. Position brake drum and tighten screw.
14. Tighten adjuster bolt to 25 Nm (18 lbf.ft) then
back off 1 1/2 turns.
15. Check that brake drum is free to rotate.
16. Fit propeller shaft. See PROPELLER SHAFTS,
Repair.
17. Top-up transfer gearbox oil.
GASKET - REAR OUTPUT SHAFT HOUSING
Service repair no - 41.20.55
Remove
1. Drain transfer gearbox oil. See
MAINTENANCE ,
2. Remove rear output shaft seal. See this
Section.
3. Mark output shaft housing to main casing for
assembly purposes.
4. Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
5. Clean output shaft housing, mating face on main
casing and sealant from bolt threads.
6. Apply Hylosil RTV 102 to mating flange on
output shaft housing.
7. Fit output shaft housing to main casing ensuring
that splines of output shaft are engaged in
differential.
8. Apply Loctite 290 to bolt threads.
9. Fit bolts and tighten by diagonal selection to 45
Nm (33 lbf.ft).
10. Fit rear output shaft seal. See this Section.
11. Fill transfer gearbox with oil. See
MAINTENANCE ,
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TRANSFER GEARBOX
13
REPAIR
SWITCH - LOW DETECT
Service repair no - 41.30.05
Remove
1. Remove battery cover.
2. Disconnect battery negative lead.
3. Remove gear lever knobs.
4. Remove gearbox tunnel carpet.
5. Remove gear lever(s) gaiter.
6. Release and remove insulation pad from around
gear levers.
7. Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
8. Release bulkhead carpet from LH side of tunnel
and move aside.
9. Remove 2 bolts securing hand-brake lever to
body and move lever aside.
10. Remove 13 screws securing tunnel cover.
11. Release and remove tunnel cover.
12. Release switch multiplug from bracket on
transfer gearbox, disconnect from harness.
13. Remove switch.
Refit
14. Clean switch and mating face on transfer
gearbox.
15. Fit nut/spacer to switch with counterbore
positioned towards switch head.
16. Apply Hylomar PL32 sealant to switch threads.
17. Fit switch and tighten to 24 Nm (19 lbf.ft).
18. Connect multiplug to harness.
19. Fit and align tunnel cover, fit and tighten screws.
20. Position hand-brake lever and tighten bolts to 25
Nm (18 lbf.ft).
21. Secure bulkhead carpet to LH side of tunnel.
22. Position relay/fuse panel, fit spacers and tighten
screws.
23. Fit insulation pad around gear levers.
24. Fit gear lever (s) gaiter.
25. Fit gearbox tunnel carpet.
26. Fit gear lever knobs.
27. Reconnect battery negative lead.
28. Fit battery cover.
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PROPELLER SHAFTS
1
REPAIR
PROPELLER SHAFT - FRONT
Service repair no - 47.15.02
Remove
1. Remove underbelly panel. See CHASSIS AND
BODY, Repair.
NOTE: To remove the underbelly panel,
the propeller shaft has to be released from
the front differential flange.
2. Mark propeller shaft to transfer gearbox.
3. Remove 4 nuts securing propeller shaft to
transfer gearbox flange.
4. Remove propeller shaft.
Refit
5. Clean propeller shaft flanges and mating faces.
6. Position propeller shaft to transfer gearbox
flange and tighten nuts to 48 Nm (35 lbf.ft).
7. Fit underbelly panel. See CHASSIS AND
BODY, Repair.
PROPELLER SHAFT - REAR
Service repair no - 47.15.03
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Using a centre punch, mark relationship of
propeller shaft flanges.
3. Remove 4 nuts securing propeller shaft to park
brake flange.
NOTE: Rotation of propeller shaft may be
required during the above procedure.
4. Remove 4 nuts and bolts securing propeller
shaft to rear axle flange.
NOTE: Rotation of propeller shaft may be
required during the above procedure.
5. Release propeller shaft from park brake.
6. Remove propeller shaft.
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