Removal/Installation

Remove

1. Position vehicle on a four post lift.
2. Release fixings and remove battery cover.
3. Disconnect battery earth lead.





4. Release clips securing cooling fan cowl and remove cowl.
5. Automatic models: Remove window switch pack.
6. Manual models: Remove center console.





7. Manual models: Remove 6 nuts securing gaiter ring and remove gaiter ring and gaiter. Remove 2 bolts securing gear lever and remove lever.





8. With the handbrake released, remove clip and clevis pin securing handbrake cable to handbrake.
9. Raise vehicle and release handbrake cable and grommet from tunnel.
10. Drain gearbox fluid.
11. Drain transfer box oil.
12. Petrol models: Remove exhaust front pipe.
13. Diesel models: Remove chassis crossmember.





14. Remove 4 bolts securing transmission mounting assembly and remove assembly.
15. Support engine and gearbox with transmission lack.





16. Remove 4 bolts securing rear propeller shaft guard and remove guard.
17. Mark transfer box and propeller shaft flanges to aid re-assembly.
18. Raise one wheel on each axle to allow rotation of propeller shafts.





19. Remove 4 nuts from each propeller shaft flange.
20. Release propeller shafts and tie aside.
21. Lower transmission for access.





22. Automatic models: Remove split pin securing gear selector cable trunnion to gearbox lever and release trunnion.
23. Remove 2 bolts securing gear selector cable abutment bracket and harness support bracket to gearbox, and position selector cable and brackets aside.





24. Remove banjo bolt securing breather pipe to transfer box, remove and discard sealing washer.

CAUTION: Plug the connections.

25. Disconnect 2 Lucars from transfer box oil temperature sensor.
26. Disconnect multiplugs from High/Low motor and output shaft speed sensor.
27. Release harness from 2 clips.





28. Remove bolt securing fuel pipe and purge pipe retaining bracket to transfer box and release bracket.





29. Position adapter plate LRT-99-012 to transmission lift and secure with nuts and bolts.
30. Raise and adjust transmission lift so that LRT-99-012 is correctly located to transfer box.





31. Remove 6 bolts securing transfer box to gearbox and release 2 harness clip mounting brackets.
32. Adjust transmission lift as necessary, release and remove transfer box.
33. Remove seal from transfer box casing using a suitable lever.

CAUTION: Ensure seal location does not become damaged as seal is levered from casing.

34. Remove seal from gearbox casing using a suitable lever.

Refit
35. Ensure seal location faces on gearbox are clean.
36. Lubricate oil seal lip with transmission fluid
37. Automatic models: Using LRT-44-001 fit seal to gearbox casing.
38. Manual models: Using LRT-37-014 fit seal to extension housing.
39. Ensure seal location faces on transfer box are clean.
40. Lubricate oil seal lip with transfer box oil.
41. Using LRT-41-011 fit seal to transfer box.
42. Clean transfer and gearbox mating faces and dowel and dowel holes.
43. Lubricate transfer box input shaft with transmission fluid.
44. Raise transfer box on lift and adjust angle of lift as necessary to align shafts.
45. Engage shafts and locate transfer box dowels to gearbox.
46. Fit bolts securing transfer box to gearbox and tighten to 45 Nm (33 ft. lbs.). Ensure that the 2 harness clip mounting brackets are correctly fitted when fitting bolts.
47. Secure harness to clips.
48. Align bracket securing fuel pipe and purge pipe to transfer box and secure with bolt.
49. Connect multiplugs to High/Low motor and output shaft speed sensor.
50. Connect 2 Lucars to transfer box fluid temperature sensor.
51. Clean breather pipe bolt and banjo, fit new sealing washers and tighten bolt to 15 Nm (11 ft. lbs.).
52. Align harness support bracket and gear selector cable abutment bracket to gear box, and secure with bolts.
53. Automatic models: Connect gear selector cable trunnion to gearbox lever and secure with split pin.
54. Adjust gear selector cable.
55. Raise transmission.
56. Clean propeller shaft and transfer box flanges.
57. Fit propeller shafts to transfer box flanges and align marks.
58. Fit nuts to propeller shafts and tighten to 48 Nm (35 ft. lbs.).
59. Fit rear propeller shaft guard and secure with bolts.
60. Fit and engage handbrake cable grommet into transmission tunnel.
61. Fit transmission mounting assembly and tighten bolts to 44 Nm (33 ft. lbs.).
62. Support transmission under brake drum.
63. Lower lift and remove adapter plate LRT-99-012 from lift.
64. Petrol models: Fit exhaust front pipe.
65. Diesel models: Fit chassis crossmember.
66. Connect handbrake cable to lever, fit clevis pin and secure pin with clip.
67. Manual models: Position gear lever and tighten bolts to 25 Nm (18 ft. lbs.). Fit gaiter and gaiter ring and secure with nuts.
68. Manual models: Fit center console.
69. Automatic models: Fit window switch pack.
70. Position fan cowl and secure with clips.
71. Connect battery earth lead.
72. Fit battery cover and secure with fixings.
73. Fill transfer box with oil.
74. Fill gearbox with fluid.