Defender-90-110-workshop-manual-3.pdf

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Section

CONTENTS

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Number

Page

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LT77 FIVE SPEED GEARBOX

LT230R TRANSFER GEARBOX

- Overhaul

Renew front output shaft oil seals

can be

LT95 FOUR SPEED GEARBOX AND TRANSFER BOX

LTWLT230T MAIN GEARBOX AND TRANSFER BOX

- Remove

37 I LT230T TRANSFER GEARBOX

- Overhaul LT85 gearbox

- Remove from LT85 gearbox

- Overhaul

147 I PROPELLER SHAFTS

REAR DIFFERENTIAL - NINETY HEAVY DUTY

REAR DIFFERENTIAL - NINETY

-Overhaul

FRONT DIFFERENTIAL - ONE TEN AND NINETY

-Overhaul

INTRODUCTION

This Workshop Manual covers the Land Rover Ninety and One Ten range of vehicles. It is primarily designed to

assist skilled technicians in the efficient repair and maintenance of Land Rover vehicles.

Using the appropriate service tools and carrying out the procedures as detailed will enable the operations to be

completed within the time stated in thc 'Repair Operation Times'.

The Manual has been produced in separate books; this allows the information to be distributed throughout the

specialist arcas of the modern service facility.

A table of contents in Book 1 lists the major components and systems together with the scction and book numbers.

The cover of each book details the sections contained within that book. Each section starts with a list of operations in

alphabetical order.

The title page of each book carries the part numbers required to order replacement books, binders or complete

Service Manuals. This can be done through the normal channels.

REFERENCES

References to the left- or right-hand side in the manual are made when viewing the vehicle from the rear. With the

engine and gearbox assembly rcmovcd, the water pump end of the enginc is referred to as the front.

To reduce repetition, operations covcrcd in this manual do not include reference to testing the vehicle after repair. It

is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out

(7:

particularly where safety related items are conccrned.

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DIMENSIONS

The dimensions quoted are to design engineering spccification. Alternative unit equivalents, shown in brackets

following the dimensions, havc bccn converted from the original specification.

During thc pcriod of running-in from new, ccrtain adjustments may vary from the specification figurcs given in this

Manual. These adjustments will be re-set by the Distributor or Dealer at thc Aftcr Sales Service, and thercal'ter

should be maintained at the figures spccified in the Manual.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential that only Land Rover parts are used.

Attention is particularly drawn to the following points concerning rcpairs and the fitting of replacement parts and

accessories:

Safety features embodied in the vehicle may be impaired if other than Land Rover parts are fitted. In certain

territories, legislation prohibits the fitting of parts not to the vehiclc manufacturer's specification. Torque wrench

setting figures given in the Repair Operation Manual must be strictly adhered to. Locking devices, where specified,

must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. Owners

purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the vehicle

conform to mandatory requirements existing in their country of origin. The terms of the Owners Service Statement

may be invalidated by the fitting of other than Land Rover parts.

All Land Rover parts havc the full backing of the Owners Service Statement.

Land Rover Distributors and Dealers are obliged to supply only Land Rover service parts.

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POISONOUS SUBSTANCES

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be

consumed and should as far as possible be kept away from open wounds. These substances among others include

antifreeze, brake fluid, fuel, windscreen washer additives, lubricants and various adhesives.

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled

safe!y. It 2!so oll!!iReS !he ather are2s of risk which mut not be ignored.

This information is issued for basic guidance only, and in any case of doubt appropriate enquiries should be made of

your local Fire Officer.

GENERAL

Petrol/gasoline vapour I S highly flammable and in confined spaces is also very explosive and toxic.

When petroVgasoline evaporates it produces 150 times its own volume in vapour, which when diluted with air

becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can

readily be distributed throughout a workshop by air current, consequently, even a small spillage of petrol/gasoline is

potentially very dangerous.

Always have a fire extinguisher containing FOAM CO2 GAS, or POWDER close at hand when handling or draining

fuel, or when dismantling fuel systems and in areas where fuel containers are stored.

Always disconnect the vehicle battery BEFORE carrying out dismantling or draining work on a fuel system.

Whenever petroVgasoline is being handled, draincd or stored, or when fuel systems are being dismantled all forms of

ignition must be extinguishcd or removed, any head-lamps used must be flameproof and kept clear of spillage.

NO ONE SHOULD BE PERMITTED TO REPAIR COMPONENTS ASSOCIATED WITH PETROL!

GASOLINE WITHOUT FIRST HAVlNG HAD SPECIALISTTRAINING.

FUEL TANK DRAINING

WARNING: PETROL/GASOLINE MUST NOT BEEXTRACTED OR DRAINED FROM ANY VEHICLE WHILST

IT IS STANDING OVER A PIT.

Draining or extracting petroligasoline from vehicle fuel tank must be carried out in a well ventilated area.

The receptacle used to contain the pctrol/gasoline must be more than adequate for the full amount or fuel to be

extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storagc area

which meets the requirements of local authority regulations.

WHEN PETROL/GASOLINE HAS BEEN EXTRACTED OR DRAINED FROM A FUEL TANK THE

PRECAUTIONS GOVERNING NAKED LIGHTS AND IGNITION SOURCES SHOULD BE MAINTAINED.

FUEL TANK REMOVAL

On vehicles where the fuel line is secured to the fuel tank outlet by a spring steel clip, it is recommended that such

clips are released before the fuel line is disconnected or the fuel tank unit is removed. This procedure will avoid the

possibility of residual petrol fumes in the fuel tank being ignited when the clips are relcased.

As an added precaution fuel tanks should havc a PE'I'ROL/GASOLINE VAPOUR warning label attached to them

as soon as they are rcmovcd from the vehicle.

FUEL TANK REPAIR

Under no circumstances should a repair to any tank involving heat treatment be carried out without first rendering

the tank SAFE, by usingone of the following methods:

STEAMING: With the filler cap and tank unit removed, empty the tank. Steam thc tank for at least two hours

with low pressure steam. Position the tank so that condensation can drain away freely, ensuring that any

sediment and sludge not volatiscd by the steam, is washed out during the steaming process.

BOILING: With the filler cap and tank unit removed, empty the tank. Immerse the tank completely in boiling

water containing an effective alkaline degreasing agent or a dctcrgent, with the water filling and also

surrounding the tank for at least two hours.

After steaming or boiling a signed and dated label to this effect should be attached to the tank.

SPECIFICATION

Purchasers are advised that the specification details set out in this Manual apply to a range of vehicles and not to any

one. For the specification of a particular vehicle, purchasers should consult their Distributor or Dealer.

The Manufacturers reserve the right to vary their specifications with or without notice, and at such times and in such

manner as they think fit. Major as well as minor changes may be involved in accordance with the Manufacturer's

policy of constant product improvement.

Whilst every effort is made to ensure the accuracy of the particulars contained in this Manual, neither the

Manufacturer nor the Distributor or Dealer. by whom this Manual is supplied, shall in any circumstances bc held

liable for any inaccuracy or the consequences thereof.

COPY RIGHT

0 Land Rover Limited 1984

form, electronic, mechanical, photocopying, recording or other means without prior writtcn permission of Land

Rover Limited, Service Department, Solihull, England.

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Ill

Special Service Tools

The use of approvcd special scrvice tools is important. Thcy are essential if scrvicc opcrations arc

to be carricd out cfficicntly, and safely. The amount of timc which thcy save can be considcrable.

Every special tool is designcd with the closc co-operation of Land Rover Ltd., and no tool is put

into production which has not been tested and approvcd by us. New tools are only introduced

wherc an operation cannot be satisfactorily carried out using cxisting tools or standard equipment.

The user is therefore assurcd that the tool is ncccssary and that it will perform accuratcly,

efficiently and safely.

Special tools bullctins will be issued periodically giving details of new tools as thcy are introduced.

All orders and enquiries from the United Kingdom should be sent dircct to V. L. Churchill.

Overseas orders should be placed with the local V. L. Churchill distributor, whcrc one exists.

Countries whcrc thcrc is no distributor may ordcr dircct from V. L. Churchill Limited, PO Box 3,

Daventry, Northants, England NNll 4NF.

Thc tools rccommended in this Workshop Manual are listed in a multi-language, illustrated cataloguc obtainable from

Messrs. V. L. Churchill at thc above addrcss under publication number 221?!2!84 or from Land Rover Ltd., under part

number LSM0052TC from the following address, Land Rover Publication Scrvicc, P.O. Box 534, Erdington, Birmingham,

B24 OQ5.

LT77 FIVE SPEED GEARBOX

1371

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TRANSFER BOX - FOUR CYLINDER MODELS

Release the connection to the front pipe at

the flange.

Release the connection to the rear section at

the flange immediately behind the silencer.

Remove the 'U' bolt retaining the pipe to the

bracket attached to the transfer box.

16. Mark the flanges for reassembly and disconnect the

front propeller shaft from the transfer box.

17. Similarly, disconnect the rear propeller shaft.

18. Disconnect the speedometer cable from thc rear of

the transfer box.

19. Disconnect the handbrake inner cable by removing

the split pin and clevis pin.

20. Slacken the retaining nuts and release the

handbrake outer cable from the bracket.

21. Remove the two bolts and withdraw the clutch

slave cylinder from the bell housing.

22. Manufacture a cradle to the dimensions given in

the drawing and attach it to a transmission hoist.

To achieve balance of the transmission unit when

mounted on the transmission hoist, it is essential

that point A is situated ovcr the centre of the lifting

hoist ram. Drill fixing holes B to suit hoist table.

Secure the transmission unit to the lifting bracket

at point C, by means of the lower bolts retaining

the transfer gearbox rear cover.

23. Remove the bottom two bolts from the transfer

box rear cover and use them to attach the rear end

of the cradle to the transfer box. Ensure that the

tube in the centre of the cradle locates over the

extension housing drain plug.

24. Raise the hoist just enough to take the weight of

the transmission.

(a)

1. Install the vehicle on a ramp.

2. Disconnect the battery.

3. Remove the gear lever knob.

4. Remove the transfer and differential lock knob.

5. Remove the gear lever cover.

6. Remove the 10 mm Nyloc nut and plain washer.

Mark the gear lever spline setting and dctach the

gear lever and gaiter from the splined lower gear

lever.

7. Select high range to prevent the transfer gearbox

selector lever fouling the tunnel when removing the

gearbox.

8. Remove the bonnet.

9. Remove the nuts and bolts retaining the fan cowl to

the engine and move the cowling forward, clear of

(b)

(c)

the engine.

10. Release the transmission breather pipes,

speedometer cable, and starter motor harness from

clips at rear of the engine.

11. Release clamp holding heater pipes on top of

engine to prevent heater inlet pipe fouling

bulkhead.

12. Raise the ramp.

13. Remove the eight nuts and bolts securing the

chassis cross member and using a suitable means of

spreading the chassis, remove the cross member.

14. Place a suitable container under the transmission,

remove the three drain plugs, allow the oil to drain

and refit the plugs. Clean filter on the extension

housing plug before refitting.

15. Remove the intermediate exhaust pipe and silencer

section as follows:

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0 6.19

5.0

0-25

6.0

5.0

6.0

508.0

UATERIAL ANC WELDING SPLCIFICATION

222.0

Steel Plate 8s 1440 (Glade 1 or 14)

Tuhr HS 4888 (Part 2)

Arc Welding HS 5135

ST 637M

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REMOVE LT77 FIVE SPEED GEARBOX AND 230R

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0 019

0-25

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