TD5 Defender
MANUAL GEARBOX
5
REPAIR
14. Remove bolt and special washer securing lower
gear lever in housing.
15. Carefully withdraw lower gear lever from the
housing ensuring that the spring loaded nylon
pad is retained during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
16. Release nylon pad, recover spring.
Refit
17. Clean components, gear change housing and
mating face on remote housing.
18. Apply multi - purpose grease to ball pin and fit
spring and nylon pad.
19. Depress nylon pad against spring pressure,
position lower gear lever in housing with the
nylon pad facing away from bias spring location.
20. Fit lower gear lever retaining bolt and special
washer and tighten bolt to 10 Nm (7 lbf.ft).
21. Fit upper gear lever to lower gear lever and
tighten nut to 25 Nm (18 lbf.ft).
22. Drift new roll pin into housing.
23. Fit bias spring adjusting screws and locknuts.
24. Using a suitable piece of tubing, locate both
ends of bias spring over ball pins.
25. Fit new gasket to remote housing, position gear
change housing to remote housing and tighten
bolts to 25 Nm (18 lbf.ft).
26. Adjust bias springs. See Adjustment.
27. Fit and align tunnel cover, fit and tighten screws.
28. Secure bulkhead carpet to LH side of tunnel.
29. Position relay/fuse panel, fit spacers and tighten
screws.
30. Fit insulation pad around gear levers.
31. Fit gear lever gaiter(s).
32. Fit gearbox tunnel carpet.
33. Fit gear lever knobs.
