Gearbox
Remove
1. Raise vehicle on four post lift.
2. Disconnect battery negative lead.
3. Petrol Vehicles: Release 2 clips securing cooling fan cowling to radiator. Remove cowl.
4. Remove center console.
5. Remove 6 nuts securing gaiter ring. Remove ring and gaiter
6. Remove 2 bolts securing gear lever. Remove lever.
7. Remove handbrake cable clevis pin.
8. Release handbrake cable from grommet in tunnel. Refit cable grommet to tunnel.
9. Raise lift. Drain gearbox and transfer box oil.
10. Remove exhaust front pipe.
11. Diesel Vehicles: Remove chassis crossmember.
12. Remove 4 bolts securing rear propeller shaft guard. Remove guard.
13. Mark transfer box and propeller shaft flanges to aid re-assembly.
14. Raise one wheel on each axle to allow rotation of propeller shafts.
15. Remove 4 nuts and bolts from each flange. Disconnect propeller shafts. Tie aside.
16. Disconnect 2 Lucars from transfer box oil temperature sensor.
17. Disconnect multiplugs from high/low motor and output shaft speed sensor.
18. Disconnect multiplugs from reverse and neutral switches.
19. Release harness from clips.
20. Remove 3 bolts securing oil cooler pipe adapter to gearbox.
21. Release adapter, collect 2 O-rings and discard. Plug connections.
22. Remove banjo bolts securing breather pipes to gearbox and transfer box.
23. Collect 2 sealing washers from each union and discard. Plug pipes and connections.
24. Tie breather and oil cooler pipes aside.
25. Position adapter plate to transmission lift. Secure with bolts.
26. Raise transmission lift into position. Secure adapter plate to gearbox mounting bracket holes with 4 bolts.
27. Remove transmission stand.
28. Lower transmission for access.
CAUTION: Place a wooden block between, axle case and sump to support engine.
29. Remove bolt securing harness bracket to gearbox.
30. Remove 8 bolts securing gearbox to bell housing.
CAUTION: Do not allow the weight of the gearbox to be supported by the clutch.
31. With assistance, release gearbox from clutch plate splines.
32. Lower transmission assembly away from vehicle.
33. Do not carry out further dismantling if component is removed for access only.
34. Attach lifting eyes to transmission.
35. Attach hoist to lifting eyes. Take weight of transmission.
36. Remove lift adapter. Hoist transmission assembly onto bench.
37. Fit lifting eye to transmission brake drum. Raise gearbox on end.
CAUTION: Position packers beneath bell housing extension to provide clearance for input shaft.
38. Remove 6 bolts securing transfer box to gearbox. Release from 2 ring dowels. Remove transfer box.
39. Remove 2 bolts securing clutch release bearing spigot. Remove spigot.
40. Lay gearbox on side. Position bell housing extension over edge of bench.
41. Remove 6 bolts securing bell housing extension. Release from 2 ring dowels. Remove from gearbox.
42. Ensure mating faces are clean.
43. Clean release bearing spigot. Lightly coat running surface with grease.
44. Position bell housing extension to gearbox. Engage ring dowels. Secure with bolts. Tighten to 45 Nm (33 ft. lbs.)
45. Position clutch release bearing spigot. Secure with bolts. Tighten to 18 Nm (13 ft. lbs.)
46. Place gearbox on end. Position transfer box.
47. Engage transfer box to ring dowels. Secure to gearbox with bolts. Tighten to 45 Nm (33 ft. lbs.)
48. Place transmission on side. Fit lifting eyes.
49. Raise transmission to lift adapter. Secure to adapter plate with bolts.
50. Detach hoist. Remove lifting eyes.
Refit
51. With assistance, depress clutch pedal. Align clutch friction plate with either: LRT-12-001 Petrol models or LRT-12-123 Diesel models.
52. Release clutch pedal. Remove aligning tool.
53. Select gear to aid input shaft alignment.
54. Position transmission to engine. Engage input shaft to friction plate splines.
CAUTION: Do not allow the weight of the gearbox to be supported by the clutch.
55. Engage bell housing ring dowels. Secure gearbox to bell housing with bolts. Tighten to 45 Nm (33 ft. lbs.)
56. Select neutral.
57. Raise transmission. Support under brake drum with transmission jack.
58. Remove transmission lift adapter. Remove lift.
59. Untie breather and oil cooler pipes.
60. Remove plugs from pipes pipes and connections.
61. Fit new O-rings to oil cooler pipe adapter. Position adapter to gearbox. Secure with bolts.
62. Fit new sealing washers to breather pipes. Position pipes. Secure with banjo bolts.
63. Position harness bracket to gearbox and secure with bolt.
64. Secure harness to clips.
65. Connect multiplugs to reverse and neutral switches.
66. Connect multiplugs to high/low motor and output shaft speed sensor.
67. Connect Lucar terminals to transfer box oil temperature sensor.
68. Raise one wheel on each axle to allow rotation of propeller shafts.
69. Position propeller shafts to transfer box flanges. Align marks.
70. Secure shafts with nuts and bolts. Tighten to 48 Nm (35 ft. lbs.)
71. Fit rear propeller shaft guard. Secure with bolts.
72. Route handbrake cable through grommet in transmission tunnel.
73. Diesel Vehicles. Fit chassis cross member.
74. Fit exhaust front pipe.
75. Refill gearbox and transfer box fluids.
76. Fit seal around gearbox remote housing to transmission tunnel aperture.
77. Connect handbrake cable to lever. Secure with clevis pin and clip.
78. Position gear lever. Secure with bolts. Tighten to 25 Nm (18 ft. lbs.)
79. Fit gaiter and ring. secure with nuts.
80. Fit center console.
81. Petrol Vehicles. Position radiator cooling fan cowling. Secure with clips.
82. Reconnect battery negative lead.