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.

.

Рассказать друзьям