Defender 90 / 110 / 130. Instruction - page 76
TRANSFER GEARBOX
218. Repeat above procedure and fit the rear taper
roller bearing.
219. Lubricate both bearings with oil.
220. Fit input gear assembly into the transfer box from
t h e
rear (gear end
first).
Obtaining bearing pre-load
-
with intermediate gear
cluster removed
221. Secure the mainshaft bearing housing in the vice.
222. Press out the rear input gear bearing cup and
223. Clean the main bearing housing and measure
224. Fit the original shim to the main bearing housing.
225. Locate
rear
bearing cup on the main bearing
226. Apply grease to the gasket and fit onto the
2-27. Fit the main bearing housing and tighten the two
remove the shim behind it.
original shim, noting its thickness.
housing and press
it
fully
home.
t
ransfcr box casing
.
securing screws
to the specified torque.
.
...
.
,
.
.
,
.
...
.
. I .
.
...
Wind
around
rotate the input gear. A pull of 1,4 to 3,6
( 3 to
8 Ib) is required on the spring balance. This
applies to new
or used bearings.
229. If the reading obtained is outside the above
limits the original shim must be changed
accordingly.
230. Remove t h e two screws retaining the mainshaft
bearing housing.
231. Press out the rear bearing cup from the bearing
housing and remove and discard
original shim.
232. Select a shim to the required thickness to obtain
t h e
correct pre-load
of
to
to
0.003 in) on reassembly.
233.
Fit the shim to the main bearing housing
then
press the rear bearing cup into position.
234.
Fit the main bearing housing and tighten the two
securing screws
to the specified torque.
235. Grease and fit P.T.O. cover gasket and finally
fit
the P.T.O. cover securing
it
with six bolts (with
plain washers) to the specified torque.
Intermediate gear assembly
-
Keassembly
236. First
the needle roller bearings and spacer
from the gcar assembly.
237. Clean the parts, including the thrust washers and
lock plate and examine for wear or damage,
renew as necessary. Refer to D A T A at end
of
section
for thrust washer thickness.
238. Fit the
ring to
t h e
intermediate shaft.
239. Fit the
'0'
ring into the front of
t h e
transfer case.
240. Lubricate thrust washers, bearings, shaft and
241. Fit needle bearings with spacer interposed.
spacer.
If the bearings have plastic cages, the flangcd
of each cage must face the thrust washers, when
fitted.
242. Fit front thrust washer to slot in transfer (plain
side to case).
243. Locate gear assembly partially into the transfer
case
so that
it
rests on the front thrust washer.
244. Locate rear thrust washer (plain side uppermost)
into slot in transfer case.
245. Gently push gear assembly into mesh.
246. Using a screwdriver through the intermediate
shaft hole guide the locating tab on the rear thrust
washer into the slot provided
in
the transfer case.
247. Align gear and thrust assembly and slide the
intermediate shaft into the transfer box from the
rear.
248. Align the shaft so that the lock plate slot
in
end is on
top.
.
.
.
NOTE: The pre-load can only be measured while
the Transfer gearbox is separated from
the
main
gear
box.
TRANSFER GEARBOX
249. Apply Loctite 290 to the lock plate bolt threads.
Locate lock plate
into position and fit securing
bolt (with spring washer).
250.- Using a screwdriver via the bottom of the transfer
case lift up the gear assembly and measure the
end-float with feeler gauges. This should be
between
and
(0.003 and 0.014 in).
251. Grease and
fit
the bottom
gasket.
252. Apply Loctite 290 to the ten bottom cover fixing
253.
Clean and fit the bottom cover, using
the
bolts
bolts only.
(with spring washers).
Transmission brake assembly
254. Clean brake backplate and oil drip plate and
apply silicone rubber sealant. Locate the
on
rear output
housing
so
that
brake operating lever
is on the
right-side rear.
255. Fit the four Brako Durlok bolts, the lower two
with plain washers, also retain t h e oil drip plate.
Tighten
to
specified torque.
256. Clean and
fit
brake drum and
fit
the two
countersunk retaining screws.
34
257,261
259
\
gear change housing
-
Overhaul
(Instructions 262 to 298)
Dismantling
262. Remove the split pin from the clevis pin at the top
of the differential lock cross shaft lever which
secures it
to the gear change cross shaft.
263. Remove the washer and clevis pin and the
rattle nylon strip.
264. Mark the position of the
gcar change
operating arm on the splined shaft o f the gcar
change crank arm.
265. Slacken the clamp bolt and remove the operating
arm.
266. Remove the four bolts from the top of the gear
change housing and
iift
off
the grommet
grommet, gate plate and gasket.
267. Remove the split pin from
t h e
gear change crank
arm clevis pin and remove the clevis pin.
268. Remove the circlip from
t h e
gear change
lever bush.
269. Withdraw the gear change lever from the housing,
with ball and
bush.
Differential lock switch adjustment
257. Select differential locked position by moving the
differential lock lever towards the right side of the
transfer box.
258. Obtain a battery and connect a test lamp circuit to
the differential lock switch.
Slacken the lock nut off and screw
in the lock
switch until the bulb is illuminated.
260. Turn the lock switch another half turn and tighten
the lock nut against t h e housing.
261. Disconnect t h e battery and move the differential
lock lever towards the left side of the transfer box
to disengage
differential lock.
TRANSFER GEARBOX
...
..
...
270. Rcmove the two countersunk screws from t h e
271. Remove the housing end cover.
Remove the two
rings from the end cover.
273. Remove
cross shaft from the housing.
274. Compress t h e detent spring and remove
t h e
gcar
change
from
inside the housing.
housing end cover.
Reassem biy
279.
Fit the two
rings to the housing end cover.
280. Fit the two
rings to the gear change crank arm.
281. Lubricate
rings with oil.
282. Clip the detent spring onto the detent plate.
283. Fit detent plate assembly into housing and retain
from outside with two Nyloc nuts
(with
plain
washers).
284. Compress
detent spring and f i t the gear
change crank arm
in
t h e
housing.
285.
Fit cross shaft into position locating end in the
crank arm.
286. Fit the housing end cover to support the other end
of the cross shaft.
287. Finally secure the housing end cover with the two
countersunk screws.
288. Before refitting the gear change lever remove the
clevis pin bushes and the Nylon socket bush and
ball.
289. Clean all parts, examine for
o r damage,
renew as necessary.
Fit and grease gear lever ball and Nylon socket
bush to gear lever.
291. Fit and grease clcvis pin bushes.
292. Locatc gear change lever assembly in cross shaft
(do not
fit
socket bush retaining circlip at this
stage).
293. Align gear change lever end with crank arm fork
ensuring
the gear lever is
and
fit
clcvis and split pin.
294. Finally secure Nylon socket bush with circlip.
295. Grease and
fit
gasket to
change housing face.
296.
Fit the
plate.
297. Fit the grommet.
298. Fit the grommet plate and retain with the four
securing bolts (with spring washers).
275. Remove t h e two
‘0’
rings from the crank arm.
276. Remove and discard the two Nyloc nuts retaining
277. Remove the detent plate and spring from the
278. Clean all parts,
for wear or damage,
the detent plate.
housing.
renew as necessary.
35
TRANSFER GEARBOX
299. Before refitting the
connecting rod and
gear change operating arms remove the respective
clevis pins and Nylon bushes. Clean and examine
for wear
or damage, renew as necessary.
300. Grease and fit the Nylon bushes to
selector and gear change opcrating arms.
301. Assemble both operating arms to the connecting
rod with clcvis pin, plain washer and split pin.
302. Slacken the gear change operating arm clamp bolt
and fit the operating arm
on to the splined shaft
projecting from the
gear change
housing, carefully aligning
it
to the marks
on both
303. Tighten the clamp bolt to the specified torque.
304. Before refitting the differential lock cross shaft
lever and pivot bracket remove the respective
clevis pins and Nylon bushes. Also remove the
split pin retaining the cranked lever and
disconnect it. Clean and examine for wear
or
damage, renew as necessary.
305.-
Fit
the cranked lever to the bottom of
cross
shaft lever and secure with a new split pin (with
plain washer).
NOTE: Early gearboxes were fitted with
a
short
connecting link secured by a ‘Nyloc’ nut.
306. Grease and
fit
t h e
Nylon
bushes to the middle
pivot of the cross shaft lever.
307. Fit the cross shaft lever to
(loose) pivot
bracket with the clevis pin, washer and split pin.
308. Fit the cross shaft lever fork (top) to
gear
change cross shaft.
309. Locate the anti-rattle Nylon strip and
fit
t h e
clevis
pin, plain washer and split pin.
310. Fit the cranked lever,
at
bottom of the
differential lock cross shaft lever, to the lock lever
and retain the clevis pin and plain washer with a
new split pin.
311. Grease and
fit
the Nylon bushes to the operating
arm on the selector housing cross shaft.
Adjustment of
connecting rod
312.
313.
314.
316.
317.
318.
319.
36
This operation is carried out in situ or on the
bench, after assembly to the main gearbox.
Remove the
four bolts from the top of the gear
changc housing and lift off
gear changc lever
grommet plate and the gcar change lever
grommet. Replace the four bolts
to
retain the gate plate in position.
Check that
t h e
gear lever does not foul
t h e
gate
plate when high or low range is selected.
If
adjustment is required carry out the following
procedure.
*Slacken off the connecting rod locknuts.
Move gear change lever into high range
(rearwards) and move the operating arm on the
selector housing cross shaft into high range
(forwards).
Tighten
Check that the gear change lever does not foul the
gate plate
in this position.
Engage and check low range in the same way.
320. After adjustment return the gear change lever to
the high range position.
321. Remove the four bolts retaining the gate plate and
refit the grommet and grommet plate.
322. Refit the four bolts (with spring washers).
On early versions of the transfer gearbox a different
connecting rod fork end was used with a single
locknut.
In
this case the following method of
adjustment is recommended.
(a) Disconnect t h e top of the differential lock
cross shaft lever from the gear change cross
shaft.
(b) Remove the four bolts retaining the gear
change housing to the
gear change
housing on
the
main gearbox.
(c) Lift up the housing assembly (with the
connecting rod attached) and rotate
it
as
required
to vary the length of
the
connecting
rod.
Transfer box mounting
-
Refitting
323. Fit
rubber mounting plate to the right sidc of
the front output housing by fitting the four
securing bolts (with new lock tabs).
Handbrake linkage
-
Refitting
324. Locate the handbrake linkage bracket
in
position
on the right hand side of the transfer box casing
and secure
as follows.
325. Fit the two bolts (with spring washers) and
distance pieces to retain the front sidc of the
linkage bracket.
ST
326. Fit the two bolts (with spring washers) to secure
the rear end
of the linkage bracket. The lower
bolt is shorter.
327.
Insert the clevis pin through
brake operating
lever, fit the handbrake link, plain washer and
split pin.
.