Defender (1999-2002). Manual — part 79
MANUAL GEARBOX
11
REPAIR
Refit
44. Clean gearbox to engine mating faces, dowels
and dowel holes.
45. With assistance raise gearbox on jack and align
to clutch and engine.
46. Fit lower bolts securing clutch housing to engine
and tighten to 50 Nm (37 lbf.ft).
NOTE: Do not fit upper bolts at this stage.
47. Fit earth leads and secure with bolt.
48. Connect Lucars to differential lock switch,
multiplug to reverse light switch, position
multiplug to bracket and connect low ratio detect
multiplug - if fitted.
49. Raise gearbox jack and guide transfer gearbox
lever through tunnel.
50. Secure body harness clips to bracket on top of
transfer gearbox.
51. Position battery earth lead to transfer gearbox
and tighten retaining nut.
52. Connect multiplug to speed sensor and secure
harness in clip on transfer gearbox.
53. Position mounting brackets and rubber
mountings, positioning heat shield to LH
mounting and tighten bracket bolts to 85 Nm (63
lbf.ft).
54. Position nuts to mountings and tighten to 48 Nm
(35 lbf.ft).
55. Remove 3 bolts securing support plate
LRT-99-007 to gearbox.
56. Position handbrake cable through heel board.
57. Position clutch slave cylinder, fit bolts and
tighten to 25 Nm (18 lbf.ft).
58. Clean propeller shafts and mating faces.
59. Position propeller shafts, align to marks and
tighten nuts to 48 Nm (35 lbf.ft).
60. Clean intermediate silencer and tail pipe mating
faces.
61. Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts and
tighten to 25 Nm (18 lbf.ft).
62. Refill gearbox with oil. See Adjustment.
63. Refill transfer gearbox with oil. See
MAINTENANCE ,
64. Fit exhaust front pipe. See MANIFOLD AND
EXHAUST SYSTEM, Repair.
65. Refit starter motor. See ELECTRICAL, Repair.
66. Fit bolt securing shim plate to clutch housing and
tighten 10 Nm (7 lbf.ft).
67. Position heater pipe to gearbox housing, fit
upper bolts securing clutch housing to engine
and tighten to 50 Nm (37 lbf.ft).
68. Position gearbox breather pipes to clips on
heater hose.
69. Fit air cleaner. See FUEL SYSTEM, Repair.
70. Fit cooling fan. See COOLING SYSTEM,
Repair.
71. Fit and align tunnel cover, fit and tighten screws.
72. Position relay panel, fit spacers and tighten
screws.
73. Position hand-brake lever and tighten bolts to 25
Nm (18 lbf.ft).
74. Connect handbrake cable to lever, fit clevis pin,
washer and new split pin.
75. Connect Lucar to hand-brake switch.
76. Position gaiter to handbrake lever and secure
with trim stud.
77. Locate insulation pad over gear levers and fit to
tunnel cover.
78. Align spline marks, fit gear lever to lower lever,
fit washer and secure with retaining nut.
79. Position gear lever cover.
80. Position gearbox tunnel carpet.
81. Fit gear lever and transfer gear lever knobs.
82. Reconnect battery negative lead.
83. Fit battery cover.
37
MANUAL GEARBOX
12
REPAIR
SWITCH - REVERSE LIGHT
Service repair no - 37.27.01
Remove
1. Remove gear lever knobs.
2. Remove gearbox tunnel carpet.
3. Remove gear lever (s) gaiter.
4. Release and remove insulation pad from around
gear levers.
5. Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
6. Release bulkhead carpet from LH side of tunnel
and move aside.
7. Remove 13 screws securing tunnel cover.
8. Release and remove tunnel cover.
9. Disconnect reverse light switch multiplug.
10. Remove switch and discard sealing washer.
Refit
11. Clean switch and mating face on gearbox.
12. Fit new sealing washer and fit switch to gearbox.
13. Connect reverse light switch multiplug.
14. Fit and align tunnel cover, fit and tighten screws.
15. Secure bulkhead carpet to LH side of tunnel.
16. Position relay/fuse panel, fit spacers and tighten
screws.
17. Fit insulation pad around gear levers.
18. Fit gear lever (s) gaiter.
19. Fit gearbox tunnel carpet.
20. Fit gear lever knobs.
41 - TRANSFER GEARBOX
CONTENTS
Page
ADJUSTMENT
DIFFERENTIAL LOCK WARNING LAMP SWITCH
1
. . . . . . . . . . . .
HIGH/LOW SELECTOR LINKAGE
1
. . . . . . . . . . . . . . . . . ..
REPAIR
BOTTOM COVER - TRANSFER GEARBOX - RESEAL
1
. . . . . . . . . ..
TRANSFER GEARBOX
1
. . . . . . . . . . . . . . . . . . . . . ...
GASKET - REAR COVER PLATE
6
. . . . . . . . . . . . . . . . . ...
SWITCH - DIFFERENTIAL LOCK WARNING LAMP
7
. . . . . . . . . . ...
SEAL - INPUT SHAFT
8
. . . . . . . . . . . . . . . . . . . . . . .
SEAL - FRONT OUTPUT SHAFT
9
. . . . . . . . . . . . . . . . . .
SEAL - REAR OUTPUT SHAFT
10
. . . . . . . . . . . . . . . . . .
GASKET - REAR OUTPUT SHAFT HOUSING
12
. . . . . . . . . . . . .
SWITCH - LOW DETECT
13
. . . . . . . . . . . . . . . . . . . . ..
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