Defender 90 / 110 / 130. Instruction - page 74

TRANSFER GEARBOX

Reassembling

34. Ensure that all faces

of t h e transfer box are clean.

Check that

and drain plugs are

in

position.

36. Fit the two studs which are used for part retention

of the extension housing.

37. Screw

in the ‘radial’ dowel. It is important that its

projecting blade is set

in

line

with the

tapped fixing hole centres

in the transfer box

casing.

46. Remove the speedometer driven gear and spindle

47. Remove the

ring and oil seal.

from the spindle housing.

Rear output shaft housing

-

Overhaul (Instructions 47

to 73)

Dismantling

38.

Using flange wrench

1861205 remove the flange

nut.

steel and felt washers.

NOTE: Ensure flange bolts are fully engaged in the
wrench.

38

48. Slide off the spacer and speedometer drive gear

from the output shaft.

49. Clean all parts, renew

oil

seals and Nyloc flange

nut and examine all

parts for wear or

damage, renew as necessary.

Reassembling

50. Press the output bearing into

t h e

housing. D o not

use excessive force. If necessary warm the housing
and case.

51.

Fit

the bearing retaining circlip using circlip pliers

186257.

52. Fit a new dual lip oil seal (open side inward), with

the seal in contact with the bearing circlip it

is

essential to use replacer tool 1861422.

NOTE: On early production two separate seals
were used, these should be replaced with the new
dual lip seal.

39. Remove the output shaft flange with circlip

attached. If necessary, use a two-legged puller.

NOTE: The circlip need only be released if the
flange bolts are to be renewed.

40. Remove the speedometer spindle housing. This

can be prised out with

a screw driver.

41. Remove assembly from vice and support the

housing to allow removal

of the shaft, drifting

it

out by striking the flange end

of the shaft.

driver in the

slot

provided.

1271.

retaining the bearing.

housing.

52

42.

the

catch

ring

screw

43. Prise out and discard the

using tool

44. Using circlip pliers

remove the circlip

45. Drift out the bearing from the back of t h e

M

25

TRANSFER GEARBOX

53.

Carefully charge the lips of the seal with grease.

54.

Fit

oil catch ring o n t o housing.

55.

Fit oil seal into speedometer spindle housing

(open side inwards) with a suitable

56.

Fit

ring to speedometer spindle housing.

57. Lubricate seal and

ring with

oil.

58. Locate speedometcr driven gear and spindle in

spindle housing and push into position.

59.

Slide speedometcr drive gear and spacer onto

output shaft.

60.

Fit output shaft to the bearing in the rear output

shaft housing.

Examine the flange seal track to check for any

damage that may harm the seal. Retain for fitting
later.

62. Locate speedometer spindle housing assembly in

the output shaft housing and push in flush with
housing face.

-NOTE: Before fitting the rear output shaft housing

to the transfer box casing the centre differential
rear bearing track must be fitted.

63. Drift the centre differential rear bcaring track into

the transfer box casing

in) below the

outer face of the casing. Check the depth before
proceeding.

Fitting rear output shaft housing to transfer box

64. Grease and

fit

housing gasket and locate the

housing in position

on

the transfer box.

NOTE: If the differential rear main bearing track
has been correctly fitted there will be a gap

between the housing face and the gasket at this
stage.

65.

Apply Loctite 290

to

the threads

of the six housing

securing screws, noting that the upper screw is
longer. Fit the screws (with spring washcrs)
evenly tightening them to the specified torquc.
This will press in

rear main bearing track to

the correct position and seat

Centre differential Unit

-

Overhaul

(Instructions 66 to

119)

Dismantling

66.

Detach

selector shaft and fork.

I

I

I

67. Using soft jaws secure the differential unit in a vice

with

t h e

‘stake’ nut uppermost.

68. Remove

the

metal to

removal

of

t h e

nut.

69.

Remove the ‘stake’ nut using tool
Remove the differential unit from the vice.

71. Secure hand press MS47 in vice with collars

and using button

remove

rear taper (twenty-four) roller bearing and collars
LST

47-1 for latest (twenty-three) roller bearing.

72. Substituting collars

remove front

taper roller bearing.

73. Remove the hand press from the vice.

ii

74. Remove the high range (smallest) differential

gear and its bush.

75. Mark the relationship

of the

selector

sleeve to the hub and remove the sleeve.

26

TRANSFER GEARBOX

*.I..

--

76.

Using

a suitable press behind the low range

(largest) gear carefully remove both

hub

and low range gear together. Alternatively, the
rear carrier bearing, high output gear and bush,

hub and sleeve and low output gear can

be pressed off

in one operation by supporting the

differential side of the low gear.

77.

Using

soft jaws secure the differential unit in the

vice by gripping the inner hub splines.

78.

Remove the eight retaining bolts and lift off the

front differential case.

79. Lift off the front (upper) bevel gear and thrust

washer.

80. Remove both pairs of side gears with their

respective shafts and dished washers together.

81. Lift out the remaining rear (lower) bevel gear and

thrust washer.
Remove the rear differential case from the vice.

83. Clean all parts, examine for wear or damage,

renew as necessary.

.

.

..

.

99

-

Obtaining differential backlash by checking bevel gear

end-float

84.

Using soft

jaws secure the rear differential case in

the vice by gripping the inner hub splines.

85. Ensure that all differential components are dry to

assist in checking end-float.

86. Using

a micrometer measure one of the bevel gear

thrust washers and note thickness.

87.

Fit the thrust washer and bevel gear to the rear
(lower) differential case.

88. Assemble the side gears and dished washers on

their respective shafts and fit to the rear case.

89. Measure the remaining bevel gear thrust washer,

noting its thickness.

90. Fit the thrust washer and bevel gear to the front

case.

91.

Fit and align the front differential case tightening
the eight securing bolts to the specified torque.

92. Ensure that the front bevel gear is fully in mesh by

tapping

i t

down, using

a punch through the front

differential case.

93. Measure the front bevel gear end-float with feeler

gauges through the slots provided

in

the

front

differential case. This must be between

and

(0.001 and 0.003 in) maximum.

94. Invert differential unit in vice and repeat the

above procedure (items

92

and 93) for the rear

bevel gear in the rear differential case.

95.

Return the differential unit to its former position

in

vice

i.e. with

t h e

front differentid case

uppermost.

.

27

TRANSFER

GEARBOX

96.

Remove the eight securing bolts and lift off the

Remove the

gears and thrust washers, and

98. Select correct thrust washers required for final

front differential case.

side gear

bly.

Reassembling

99. Fit the selected thrust washer and bevel gear to

the rear (lower) differential case.

100. Assemble the side gears and dished washers o n

their respective shafts and

fit

to the rear case.

101. Fit the other selected thrust washer and bevel gear

to the rear case.

102. Lubricate all parts with oil.
103. Fit and align the front differential casc, locate the

eight securing bolts and tighten to

specified

torque.

104. Finally check that the differential gears revolve

freely.

105. Place the front (outer) differential bearing on the

front differential case and press into position
using larger end

of tool

106. Invert the differential unit in the vice.
107. Fit t h e low range gear (largest) to

differential case (with its 'dog' teeth uppermost).

Press the

hub onto the splined area

of

the case. Check end-float

of low range gear. See

Data at end

of section.

109. Slide the

selector sleeve onto

hub

outer splines, observing the alignment marks.

110. Fit the bush into the high range (smallest) gear

and slide t h e bushed gear onto the rear
differential case.

end-float of high range

gear and running clearance of gear

on bush.

data at end

of section.

NOTE: If the clearances vary considerably from
those specified in the data the assembly must be
rebuilt.

111. Place the rear differential bearing on the rear

diffcrcntial case and press i n t o position using

t h e

smaller end of tool 1861424.

28

.,:;::-

-U'

112.

Fit the 'stake'

n u t

using tool

and tighten

to the specified torque.

113.

the nut flange into the slot provided.

114. Remove the differential unit from the vice.
115. Lubricate gears, bearings, sleeve and bush with

oil.

116. Clean and check

selector

fork

assembly for wear and

if

necessary.

117.

To renew the selector fork remove the square set

screw retaining

i t

to the selector shaft and ensure

any traces of Loctite are removed from the
threads.

118. Refit the selector fork

with

the fork boss towards

the three detent grooves. Align

hole

in

the

fork boss with the indent in t h e shaft nearest to

the detent grooves.

119. Apply Loctite 290 to the set screw threads and

fit

the set screw to the

torque.

Prop up the transfer box

so

that

its

front side

is

uppermost.

121.

Fit the selector fork

to

the

selector

122. Locate the differential assembly and

. ' ' -

selector fork assembly into the transfer casc. It
may be necessary to rotate the output shaft

to

ease fitment.

Fit the selector shaft detent ball and spring, apply
Loctite 290 to

t h e

detent plug threads, screw in

the detent plug until the spring is just coil bound,

then

back off two complete turns.

...

.

sleeve in the differential assembly.

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