TD5 Defender
MANUAL GEARBOX
3
REPAIR
LEVER - GEAR CHANGE
Service repair no - 37.16.04
Remove
1. Remove gear lever knob.
2. Release and remove gear lever gaiter(s).
3. Remove nut securing upper gear lever to lower
gear lever.
4. Remove upper gear lever from lower gear lever.
5. Using a suitable piece of tubing fitted over end of
bias spring, release both ends of bias spring
from ball pins.
6. Remove bolt and special washer securing gear
lever to housing.
7. Carefully withdraw gear lever from housing
ensuring that spring loaded nylon pad is retained
during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
Refit
8. Clean gear lever, housing and nylon pad.
9. Lubricate ball pin with multi-purpose grease and
fit nylon pad and spring.
10. Depress nylon pad against spring pressure,
position gear lever in housing with the nylon pad
facing away from bias spring location.
11. Fit gear lever retaining bolt and special washer
and tighten bolt to 10 Nm (7 lbf.ft).
12. Using a suitable piece of tubing fitted over ends
of bias spring, locate each end of bias spring to
ball pins.
13. Fit upper gear lever to lower gear lever and
tighten retaining nut to 25 Nm (18 lbf.ft).
14. Adjust bias spring. See Adjustment.
15. Fit gear lever gaiter(s).
16. Fit gear lever knob.
