TD5 Defender
37
MANUAL GEARBOX
2
REPAIR
7. Using a soft metal drift, carefully remove input
shaft front bearing track from front cover.
CAUTION: Take care not to damage
bearing track, if track is damaged, it will be
necessary to fit a new input shaft front
bearing.
8. Remove input shaft oil seal from front cover;
discard oil seal.
Refit
9. Using a suitable solvent clean seal recess, front
cover and gearbox mating faces; clean threads
of bolts and bolt holes.
10. Clean bearings and bearing races.
11. Lubricate a new oil seal with gearbox oil.
12. Fit oil seal using a suitable mandrel.
13. Fit input shaft front bearing track using a press
and suitable mandrel.
14. Apply sealant, Part No. STC 4404 to front cover.
15. Position front cover, apply Loctite 290 to threads
of bolts; fit new bolts and tighten by diagonal
selection to 25 Nm (18 lbf.ft).
16. Clean clutch housing mating faces, dowels and
dowel holes.
17. Position clutch housing, fit bolts and tighten by
diagonal selection to 75 Nm (55 lbf.ft).
18. Clean bearing sleeve mating faces, dowel and
dowel holes.
19. Position bearing sleeve, fit bolts and tighten to
25 Nm (18 lbf.ft).
20. Examine clutch release fork pivot points for wear
and replace as required.
21. Apply a smear of Molybdenum disulphide grease
to pivot points and position release fork.
22. Fit retaining clip ensuring it locates over pivot
point washer, fit bolt and tighten to 10 Nm (7
lbf.ft).
23. Clean release bearing and bearing sleeve
mating faces.
24. Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
25. Fit release bearing and secure with retaining
peg.
26. Fit gearbox. See this Section.
