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Defender 300Tdi (1996+). Manual - part 42

TRANSFER GEARBOX

REPAIR

23. Position 4, 30 mm (1.25 in), spacers between

top of hoist and adaptor plate, LRT-99-010, at
securing points and secure adaptor plate to
hoist.

24. Remove 4 central bolts from transfer box bottom

cover, move hoist into position and secure
adaptor plate to transfer box.

25. Adjust hoist to take weight of transfer box.

26. Remove nut securing transfer box LH mounting

rubber to chassis crossmember.

27. Remove 4 nuts and bolts securing chassis

crossmember to chassis longitudinal.

28. Remove nut securing transfer box RH mounting

rubber to chassis crossmember.

29. Remove 4 nuts and bolts securing chassis

crossmember to chassis longitudinal.

30. With assistance and using a body jack between

chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.

31. Remove chassis crossmember.
32. Remove 4 bolts from both sides and remove LH

and RH mounting brackets from transfer box.

33. Disconnect electrical leads from differential lock

switch.

34. Move the small cranked lever, for high/low

selector, upward to allow access to adjacent nut
securing transfer box to main gearbox.

35. Position a jack to support main gearbox.

CAUTION: Use a block of wood or hard
rubber pad to protect gearbox.

TRANSFER GEARBOX

REPAIR

36. Remove retaining nut, release clamp, and

disconnect speedometer cable from transfer
gearbox.

37. Remove battery earth strap retaining nut, 1 nut

and 4 bolts, securing transfer box to main
gearbox extension case.

38. Remove retaining nut securing earth leads to RH

side of transfer box.

39. Fit three guide studs, LRT-41-009, through

transfer box bolt holes to support it during
removal.

40. Lower hoist and withdraw transfer box from main

gearbox.

41. Remove transfer box.

Refit

42. Ensure joint faces of transfer box and main

gearbox are clean and guide studs, LRT-41-009,
are fitted to extension case.

43. Lubricate oil seal in joint face of transfer box.
44. Secure transfer box to adaptor plate on lifting

hoist and raise hoist until transfer box can be
located over guide studs.

45. Remove guide studs, fit battery earth strap, and

secure transfer box to main gearbox extension
case. Tighten fixings to

45 Nm (33 lbf/ft).

46. Fit electrical leads to differential lock switch.
47. Raise hoist and remove wooden block

supporting main gearbox.

48. Secure LH and RH mounting brackets to

gearbox and tighten fixings to

55 Nm (41 lbf/ft).

49. With assistance and using a body jack between

chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.

50. Position chassis crossmember and locate over

fixing studs of LH and RH gearbox mounting
rubbers .

51. Align crossmember and secure to chassis with 4

nuts and bolts on each side.

NOTE: Fit battery earth strap retaining clip
to LH top bolt.

52. Remove body jack.
53. Fit retaining nut to LH and RH mounting rubbers.

Tighten to

21 Nm (15 lbf/ft).

54. Remove 4 bolts securing hoist adaptor plate to

transfer box bottom cover.

55. Lower hoist and move aside.
56. Clean threads of the 4 bolts, coat with Loctite

290, and fit to transfer box bottom cover. Tighten
to

25 Nm (18 lbf/ft).

57. Fit earth leads to RH side of transfer box.
58. Connect differential lock control operating rod to

pivot arm.

59. Fit speedometer cable to transfer box.
60. Fit front and rear propeller shafts to transfer box.

Tighten nuts to

47 Nm (33 lbf/ft).

61. Fit intermediate silencer.

See MANIFOLD AND

EXHAUST SYSTEM, Repair, Intermediate
silencer - 90; Refit or See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 110/130; Refit .

62. Refill transfer box with recommended oil

See

SECTION 10, Maintenance, Under vehicle
maintenance

TRANSFER GEARBOX

REPAIR

63. Feed transmission brake cable through heel

board. Ensure cable grommet is correctly
located.

NOTE: Apply a soap solution to aid fitment
of cable.

64. Lower vehicle ramp.
65. Connect cable clevis to handbrake lever and fit

handbrake gaiter.

66. Connect high/low lever to operating rod.
67. Fit breather pipe banjo union to high/low

cross-shaft housing.

68. Fit cntre access panel to seat base. If fitted,

secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.

69. If fitted, reconnect multi-plug to EGR control unit

on base of centre seat cushion or cubby box.

70. Fit seat cushion or cubby box

See CHASSIS

AND BODY, Repair, Cubby box .

71. Reconnect battery.
72. Check operation of handbrake and adjust as

necessary

See BRAKES, Repair, Handbrake

cable .

TRANSFER GEARBOX

SPECIFICATIONS, TORQUE

TORQUE VALUES

NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.

Transfer gearbox
Pinch bolt - operating arm to crank arm

......................................................

End cover gear change housing

.................................................................

Bottom cover to transfer case

....................................................................

Front output housing to transfer case

........................................................

Cross shaft housing to front output housing

...............................................

Gear change housing

.................................................................................

Pivot shaft to link arm

.................................................................................

Connecting rod to adjustable clevis

...........................................................

Anti-rotation plate intermediate shaft

.........................................................

Front output housing cover

........................................................................

Pivot bracket to extension housing

............................................................

Finger housing to front output housing

......................................................

Bearing housing to transfer case

...............................................................

Brake drum to coupling flange

...................................................................

Bearing housing cover to transfer gearbox

................................................

Rear output speedometer housing to transfer gearbox

..............................

Selector finger to cross shaft high/low

.......................................................

Selector fork, high/low to shaft

...................................................................

Transmission brake to speedometer housing

............................................

Gate plate to grommet plate

.......................................................................

Gearbox to transfer case

...........................................................................

Oil drain plug

..............................................................................................

Oil filler/level plug

.......................................................................................

Differential case (front to rear)

...................................................................

Output flanges

162

...........................................................................................

Differential case rear stake nut

..................................................................

Transfer breather

.......................................................................................

Transfer box front drive flange to drive shaft

..............................................

Transfer box rear drive flange to drive shaft

..............................................

Transfer gearbox mounting brackets to chassis

........................................

Mounting brackets to transfer gearbox

......................................................

Mounting rubbers to mounting brackets

.....................................................

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