Defender (1999-2002). Manual — part 77
![](/vehicles/onond/ycatth/que/dand.png)
MANUAL GEARBOX
3
REPAIR
LEVER - GEAR CHANGE
Service repair no - 37.16.04
Remove
1. Remove gear lever knob.
2. Release and remove gear lever gaiter(s).
3. Remove nut securing upper gear lever to lower
gear lever.
4. Remove upper gear lever from lower gear lever.
5. Using a suitable piece of tubing fitted over end of
bias spring, release both ends of bias spring
from ball pins.
6. Remove bolt and special washer securing gear
lever to housing.
7. Carefully withdraw gear lever from housing
ensuring that spring loaded nylon pad is retained
during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
Refit
8. Clean gear lever, housing and nylon pad.
9. Lubricate ball pin with multi-purpose grease and
fit nylon pad and spring.
10. Depress nylon pad against spring pressure,
position gear lever in housing with the nylon pad
facing away from bias spring location.
11. Fit gear lever retaining bolt and special washer
and tighten bolt to 10 Nm (7 lbf.ft).
12. Using a suitable piece of tubing fitted over ends
of bias spring, locate each end of bias spring to
ball pins.
13. Fit upper gear lever to lower gear lever and
tighten retaining nut to 25 Nm (18 lbf.ft).
14. Adjust bias spring. See Adjustment.
15. Fit gear lever gaiter(s).
16. Fit gear lever knob.
![](/vehicles/onond/ycatth/que/ghecusi.png)
37
MANUAL GEARBOX
4
REPAIR
MECHANISM AND HOUSING - GEAR SELECTOR
Service repair no - 37.16.37
Remove
1. Remove gear lever knobs.
2. Remove gearbox tunnel carpet.
3. Remove gear lever gaiter(s)
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. Remove 4 bolts securing gear change housing,
remove housing, remove and discard gasket.
10. Using a suitable piece of tubing located over
ends of bias spring, release both ends of bias
spring from ball pins.
11. Loosen locknuts and remove bias spring
adjusting screws.
12. Drift out roll pin, remove bias spring.
13. Remove nut and extension from lower gear
lever.
![](/vehicles/onond/ycatth/que/dhept.png)
MANUAL GEARBOX
5
REPAIR
14. Remove bolt and special washer securing lower
gear lever in housing.
15. Carefully withdraw lower gear lever from the
housing ensuring that the spring loaded nylon
pad is retained during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
16. Release nylon pad, recover spring.
Refit
17. Clean components, gear change housing and
mating face on remote housing.
18. Apply multi - purpose grease to ball pin and fit
spring and nylon pad.
19. Depress nylon pad against spring pressure,
position lower gear lever in housing with the
nylon pad facing away from bias spring location.
20. Fit lower gear lever retaining bolt and special
washer and tighten bolt to 10 Nm (7 lbf.ft).
21. Fit upper gear lever to lower gear lever and
tighten nut to 25 Nm (18 lbf.ft).
22. Drift new roll pin into housing.
23. Fit bias spring adjusting screws and locknuts.
24. Using a suitable piece of tubing, locate both
ends of bias spring over ball pins.
25. Fit new gasket to remote housing, position gear
change housing to remote housing and tighten
bolts to 25 Nm (18 lbf.ft).
26. Adjust bias springs. See Adjustment.
27. Fit and align tunnel cover, fit and tighten screws.
28. Secure bulkhead carpet to LH side of tunnel.
29. Position relay/fuse panel, fit spacers and tighten
screws.
30. Fit insulation pad around gear levers.
31. Fit gear lever gaiter(s).
32. Fit gearbox tunnel carpet.
33. Fit gear lever knobs.
![](/vehicles/onond/ycatth/que/sonevil.png)
37
MANUAL GEARBOX
6
REPAIR
MECHANISM AND HOUSING - GEAR SELECTOR -
RESEAL
Service repair no - 37.16.37.01
Remove
1. Remove gear lever knobs.
2. Remove gearbox tunnel carpet.
3. Remove gear lever gaiter(s).
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. Remove 4 bolts securing gear change housing,
remove housing, remove and discard gasket.
Refit
10. Clean gear change housing and mating face on
remote housing.
11. Fit new gasket to remote housing, position gear
change housing to remote housing; fit bolts and
tighten to 25 Nm (18 lbf.ft).
12. Fit and align tunnel cover, fit and tighten screws.
13. Secure bulkhead carpet to LH side of tunnel.
14. Position relay/fuse panel, fit spacers and tighten
screws.
15. Fit insulation pad around gear levers.
16. Fit gear lever gaiter(s).
17. Fit gearbox tunnel carpet.
18. Fit gear lever knobs.
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