Defender 90 / 110 / 130. Instruction - page 14

MAINTENANCE

Renew oil filter

-

2.25 petrol and diesel engine

RENEW MAIN AND TRANSFER GEARBOX OILS

DRAIN

AND REFILL

MAIN GEARBOX

4-cylinder engines

8.

Place oil tray under engine.

9. Unscrew filter retaining bolt.

10. Remove the container.
11. Remove the element.
12. Discard the used filter element and large rubber

washer.

13.

Wash the container in kerosene.

14. Place the new filter element in the container and

reassemble the unit, using the new large rubber

washer supplied with the element.

15. Ensure that all the sealing washers are in position

and intact, and that the container is correctly
located in the adaptor.

16. Tighten the filter retaining bolt to the correct

torque.

Do

not overtighten.

Refill sump with oil

models

1. Drive the vehicle to level ground and place a

suitable container under the gearbox to catch the
old oil.

2. Remove the gearbox and extension case drain

plugs and allow the oil to drain completely. Wash
the extension case filter in kerosene and refit the

plugs using new washers, if necessary, and tighten
to the correct torque.

ST

3 .

Remove the

oil filler-level plug and inject the

approximate quantity

of new oil of the correct

make and grade until it begins to run out of the
filler-level hole.

Fit the plug and tighten to the

torque. Since the plug has tapered thread

it must not be overtightened. Wipe away any
surplus oil.

17. Check that the drain plug is tight.
18. Clean the outside of the oil filler cap, remove it

from the rocker cover and clean the inside.

19. Pour in the correct quantity of new oil

of the

correct grade from a sealed container to the high
mark

on

the dipstick and firmly replace the

cap.

20.

Run the engine and check for leaks from the filter.

Stop the engine, allow the oil to

run back into the

sump for a few minutes, then check the oil level
again and top

up if necessary.

4

MAINTENANCE

DRAIN AND RENEW 230R AND 230T TRANSFER

GEARBOX (4-cylinder engine)

1. Drive the vehicle to level ground and place a

container under the gearbox to catch the old oil.

2. Remove the drain plug and allow the oil to drain.

Fit the plug using a new washer,

if

necessary, and

tighten to the correct torque.

3. Remove the filler-level plug and inject the

approximate quantity

of the recommended oil until

it begins to run from the plug hole. Fit the level
plug and tighten only

to

the correct torque, do not

overtighten, wipe away

any

surplus oil.

DRAIN AND RENEW

MAIN

GEARBOX

engines)

Drive the vehicle to level ground and place a
container under the gearbox to catch the old

oil.

2. Remove the drain plug, washer and filter from the

bottom of the gearbox casing and allow the

oil to

drain completely.

3. Wash the filter in petrol, allow to dry and fit

to

the

casing. Using a new washer, if necessary, fit the
plug and tighten to the correct torque.

4. Remove the oil filler-level plug from the side of the

gearbox and inject the approximate quantity

of the

correct oil until it begins to run from the filler-level
hole. Clean and refit the plug using

a

new washer

and tighten to the correct torque. Wipe away any

surplus oil.

DRAIN AND RENEW

TRANSFER GEARBOX

OIL

1. Drive vehicle to level ground and place a container

beneath the gearbox to catch the old oil.

2. Remove the drain plug and allow time for the oil to

drain completely.

3. Clean and refit the drain plug using a new washer,

if necessary and tighten to the correct torque.

4. Remove the oil filler-level plug and inject the

approximate quantity

of

a recommended

oil until it

begins to run from the hole. Clean and fit the plug
and tighten to the correct torque.

Do

not

overtighten. Wipe away any surplus oil.

RENEW FRONT

AND REAR AXLE OIL

1. Drive the vehicle to level ground and place a

container under the axle to be drained.

2. Using a spanner with a

13

(0.5

in) square drive

remove the drain plug and allow the oil to drain
completely. Clean and refit the drain plug.

Remove the oil filler-level plug and inject new oil

of a recommended make and grade until it begins
to run from the hole. Clean and fit the filler-level
plug and wipe away any

surplus oil.

NOTE: Whilst the illustration shows a ‘90’ model
front differential, the procedure is the same for all

axles.

5

MAINTENANCE

RENEW SWIVEL PIN HOUSING

OIL

1. Drive the vehicle to level ground and place a

container under each swivel housing to catch the
used

oil.

2. Remove the drain plug and allow the oil to drain

completely and clean and refit the plugs.

3. Remove the oil filler-level plug and inject the

recommended make and grade

of oil until oil

begins to run from the level hole. Clean and fit the
level plugs and wipe away any surplus oil.

LUBRICATE PROPELLER SHAFTS

1. Clean all the grease nipples on the front and rear

propshaft universal joints, and sliding portion of
the rear shaft.

2 . Charge a low pressure hand grease gun with grease

of

a recommended make and grade and apply to

the grease nipples.

3. Remove the screwed plug from the front

shaft and

fit

a suitable grease nipple.

4. Disconnect one end of the front propeller shaft and

compress the sliding portion whilst applying
grease. It is necessary to compress the shaft to

prevent

filling with grease.

It

should be noted

that this sliding portion must only be lubricated at
40.000

(24,000

mile) intervals.

5.

the propeller shaft,

the grease

nipple and fit the screwed plug.

TOP-UP MANUAL STEERING

BOX

1. Remove the oil filler plug and observe the oil level

which should be

25

(1.0

in) below the top of

the filler hole.

2. If necessary top-up to the correct level with a

recommended oil. Clean and refit the plug and
wipe away any surplus oil.

ST

925M

RENEW AIR CLEANER OIL

-

2.25

litre

engines

(early models)

1. Slacken wing nut and release the clamping strap

securing the complete air cleaner.

2 . Disconnect the outlet elbow from the intake pipe

and remove the

from

vehicle.

3. Remove the oil bowl from the bottom of the

cleaner by releasing the three securing clips.

4. Clean all dirty oil and sludge from the bowl and

refill with fresh engine

oil to the level indicated by

a ring formed in the pressing; the capacity is
approximately

litre

(1.5 imperial pints).

5.

Clean the spiral in the cleaner body by swilling the

complete body in paraffin and shake off the

6. Remove and clean the air intake cap.

7.

Clean

the wire mesh filter.

8. Reassemble filter using a new scaling ring.
9. Refit the complete unit into the vehicle.

surplus.

6

MAINTENANCE

Diesel engine

TOP-UP BRAKE VACUUM PUMP

OIL

-

2.25 litre

TOP-UP CARBURETTER PISTON DAMPER

-

only

.

1. Slacken the drive belt, and the pump pivot bolts

1. Unscrew the cap on top of both suction chambers

and withdraw the damper.

2. Move the pump to an upright position and

2.

the reservoir with engine oil to within

(0.5

in) from the top of the hollow piston

rod. Refit t h e damper and secure the cap.

and nuts and slip the belt from the pulley.

temporarily tighten the nuts and bolts to maintain
this position.

3.

Turn the pump pulley

so

that the indicating marks

on the pulley hub and pump body line up.

.

.

.

...

.

.

3

4. Remove the oil level plug at the rear of the pump

and if necessary inject a recommended SAE

oil

up to the level of the hole.

5 .

Refit the level plug, and fit and tension the drive

belt.

ST

4

1008M

REAR SUSPENSION BALL JOINT

1. Apply a grease gun to the nipple using a

recommended grease.

RENEW

MAIN GEARBOX OIL

Drain and refill monthly when operating under severe

wading conditions.
T o change the

oil proceed as follows:

1.

Immediately after a

run

when the oil is warm, drain

off the oil into a container by removing the drain
plug and washer from the bottom of the gearbox

casing.

2. Remove the oil filter.

3. Wash the filter in clean fuel; allow to dry and

replace.

4. Clean and refit drain plug and washer and refill

gearbox through the oil

plug, with the

correct grade of oil, to the bottom

of the oil

hole.

For

see Data Section.

7

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