TD5 Defender
TRANSFER GEARBOX
5
REPAIR
43. If transfer gearbox is to be refitted, remove and
discard input shaft oil seal.
Refit
44. Clean mating faces of main gearbox extension
case and transfer gearbox.
45. Remove all traces of sealant from threads of
transfer gearbox securing bolts and studs.
46. Clean input shaft oil seal recess in transfer
gearbox.
47. Lubricate new input shaft oil seal with transfer
gearbox oil.
48. Using tool LRT-37-014, fit input shaft oil seal, lip
side facing inwards.
49. Ensure guide studs LRT-41-009 are fitted in
main gearbox extension case.
CAUTION: If securing studs were removed
during transfer gearbox removal, apply
Loctite 290 to threads of new studs; fit
studs and tighten to 45 Nm (33 lbf.ft).
50. Secure transfer gearbox to support plate
LRT-99-010, fit and tighten 4 bolts.
51. Raise transmission hoist until transfer gearbox
can be located over guide studs LRT-41-009.
52. Apply Loctite 290 to threads of securing bolts
and studs.
53. Fit and lightly tighten 2 nuts to secure transfer
gearbox to main gearbox extension case.
54. Remove guide studs LRT-41-009.
55. Ensuring bolts are in their original fitted
locations, fit and lightly tighten 4 bolts to secure
transfer gearbox to main gearbox extension
case.
56. Progressively tighten nuts and bolts to 45 Nm
(33 lbf.ft).
57. Position earth leads to RH side of transfer
gearbox, fit and tighten bolt.
58. Connect low ratio detect switch multiplug and
secure to bracket. Connect Lucars to differential
lock warning lamp switch.
59. Raise gearbox jack and guide transfer gearbox
lever through tunnel.
60. Connect body harness clips to bracket on top of
transfer gearbox.
61. Position earth lead to transfer gearbox, tighten
nut to 45 Nm (33 lbf.ft).
62. Connect speed sensor multiplug and secure
harness in clip.
63. Position heat shield to LH mounting, fit
mountings and brackets and tighten bolts to 85
Nm (63 lbf.ft).
64. Fit nuts securing RH and LH mountings and
tighten to 48 Nm (35 lbf.ft).
65. Position breather pipe to transfer gear box, fit
new sealing washers and tighten banjo bolts to
15 Nm (11 lbf.ft).
66. Remove bolts securing support plate to gearbox
jack.
67. Remove bolts securing LRT-99-010 to transfer
gearbox.
68. Apply Loctite 290 to threads of bottom cover
securing bolts, fit bolts and tighten to 25 Nm (18
lbf.ft)
69. Position differential lock control rod and secure
with retaining clip.
70. Clean rear propeller shaft to brake drum flange
mating faces.
