Inspecting Components

Inspecting Components

1. Clean all components, remove all traces of silicone sealant using suitable solvent and a plastic scraper.
2. Up to serial no. 288709E: Remove all traces of gasket using suitable gasket removal spray and a plastic scraper.
3. Clean all traces of Loctite and sealant from threads of bolts and tapped holes. Ensure holes are clean and dry.

CAUTION: Do not use a tap to clear threads in tapped holes.

4. Check all casings and covers for cracks and damage.
5. Replace any component found to be damaged.

Intermediate gears and shaft
1. Check gear teeth for cracks, chipping and uneven wear.
2. Check shaft for wear and threads for damage.

Mainshaft input gear
1. Check gear teeth for cracks, chipping and uneven wear.
2. Check that cross drillings in shaft are clear.

NOTE: Early transfer boxes fitted with an oil feed plate do not have cross drilled shafts. If a replacement input gear and shaft is to be fitted, the shaft will be cross drilled and it will not be necessary to fit the oil feed plate.

Defender only

3. Check that ends of dog teeth are not rounded-off or chipped.

High/Low cross shaft and housing
1. Check mating surfaces of cross shaft and drilling in housing for wear.
2. Check core plug in housing for signs of leakage or corrosion, apply Loctite 326 to replacement plug.







3. Check high/low selector finger for wear.
4. Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to 0.627 in).

Front output housing and differential lock selector
1. Check bearing track recesses in housing for damage, rectify or replace housing as necessary.
2. Check differential lock selector finger shaft and drilling in housing for wear.







3. Check differential lock selector finger for wear.
4. Measure across widest portion of finger:
Finger width = 15.90 to 15.95 mm (0.625 to 0.627 in).







5. Check differential lock selector finger groove width in differential lock selector shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64 in).







6. Check detent grooves in differential lock selector shaft for wear.
7. Check differential lock detent ball for flat spots.
8. Check detent spring for distortion.
9. Check differential lock selector fork for cracks and wear.







10. Check differential lock selector fork finger width:
Finger width = 7.92 to 7.97 mm (0.311 to 0.313 in).

11. Check differential lock selector fork spring for distortion and clips for wear and damage.
12. Check spring free length:
Free length = 84.58 mm (3.33 in).

13. Check dog clutch internal teeth and grooves for wear and damage.







14. Check dog clutch selector fork groove width:
Groove width = 8.05 to 8.20 mm (0.32 to 0.33 in)

15. Check threads and splines of output shaft for damage and wear.
16. Check dog clutch teeth on shaft for wear and damage.

Rear output housing
1. Check bearing track recess in housing for damage, rectify or replace housing as necessary.
2. Check speedometer drive and driven gears damage and wear.
3. Check splines and threads of output shaft for damage and wear.

Main casing
1. Check bearing track recesses in main casing for damage, rectify or replace casing as necessary.







2. Remove drain plug, discard sealing washer
3. Fit new sealing washer, fit drain plug and tighten to 30 Nm (22 ft. lbs.).
4. Remove filler plug, check threads for damage.
5. Fit but do not fully tighten filler plug.
6. Check that locating dowels are fitted in casing and that blade of front output housing dowel is positioned as shown.
7. Remove oil temperature switch - if fitted, remove sealant from threads of switch and main casing.
8. Apply Hylomar PL32 sealant to threads, fit and tighten switch.
9. Check high/low detent ball for flat spots.
10. Check detent spring for distortion.

Mainshaft input gear bearing housing
1. Check bearing track recess in housing for damage, rectify or replace housing as necessary.

High/Low selector fork and shaft

NOTE: There is no need to remove selector fork from shaft unless fork or shaft is to be replaced. If fork is removed, coat threads of setscrew with Loctite 290 prior to assembly.







1. Check detent grooves in shaft for wear.
2. Check high/low selector finger groove width in shaft:
Groove width = 16.0 to 16.1 mm (0.63 to 0.64 in).

3. Check high/low selector fork for cracks and wear.







4. Check high/low selector fork finger width:
Finger width = 7.37 to 7.47 mm (0.290 to 0.294 in).

Differential
1. Check sun and planet gears for wear, cracks and chipping of teeth.
2. Check cross shafts and recesses in both halves of differential carrier for damage and wear.

CAUTION: Ensure planet gears are retained with their respective shafts.

3. Check retaining ring for distortion.
4. Check splines of differential shafts for wear and damage.
5. Check teeth of high/low hub for cracks, chipping and uneven wear.







6. Check selector fork groove width in high/low hub:
Groove width = 7.5 to 7.6 mm (0.295 to 0.30 in).

7. Check splines and teeth of high/low selector sleeve for uneven wear, cracks, damage and chipping.
8. Check teeth of high and low range gears for cracks, chipping and uneven wear.
9. Check high range gear bush for wear and damage.