Removal and Replacement

Gearbox

Service Repair No - 37.20.02.99

Remove

1. Release turnbuckles and remove battery cover and cooling fan cowl.
2. Disconnect battery earth lead.





3. Remove gear lever knob and gear lever trim.





4. Remove clamp bolt and remove gear lever extension. Apply lubricant to gear lever to aid removal through grommet.
5. Remove front exhaust pipe.
6. Drain gearbox oil.
7. Drain transfer gearbox oil.





8. Remove 8 bolts securing rear cross member and remove cross member.





9. Remove 3 nuts securing intermediate silencer to tail pipe.
10. Release silencer from mounting rubbers, remove silencer and discard gasket.





11. Mark front propeller shaft to transfer gearbox and differential flanges.
12. Remove 8 nuts securing front propeller shaft to transfer gearbox and differential.
13. Remove propeller shaft.
14. Repeat above operation for rear propeller shaft.





15. Remove hand brake drum retaining screw and remove hand brake drum.
16. Remove 4 bolts from hand brake back plate, release back plate and tie aside.





17. Remove 2 bolts securing clutch slave cylinder, collect heat shield, release slave cylinder and position aside.





18. Fit support plate LRT-99-007 to gearbox jack.
19. Position gearbox jack and support plate to gearbox and secure with 3 bolts.
20. Support the weight of gearbox, remove nuts securing gearbox mountings to body.
21. Remove 8 bolts securing mountings to gearbox, raise gearbox and remove both mountings.





22. Lower gearbox sufficiently to access top of gearbox.
23. Ensure gear lever is released from grommet and no wires or pipes are trapped when gearbox is lowered.





24. Remove clevis pin and 'C' washer securing low ratio selector cable to lever and release cable from lever housing.





25. Remove 2 cable ties securing cable to fuel pipes.





26. Disconnect 2 Lucars from oil temperature sensor and disconnect reverse lamp switch multiplug.
27. Remove banjo bolts securing breather pipes and discard sealing washers.
28. Remove bolt securing breather pipe 'P' clip and release breather pipes.





29. If fitted: Disconnect 2 Lucars from differential lock switch, release and disconnect transfer box neutral sensor multiplug.
30. If fitted: Release harness from 2 retaining clips.
31. Position container to catch oil spillage





32. Remove 3 bolts securing oil cooling pipe housing to gearbox, release housing and discard 'O' rings.
33. Using a second jack support the weight of the engine.





34. Remove 14 bolts securing gearbox to engine.
35. With assistance, remove gearbox from engine.

Refit

1. Clean gearbox to engine mating faces, dowels and dowel holes.
2. Raise gear gearbox on jack and align to clutch and engine.
3. Fit bolts securing gearbox to engine and tighten to 45 Nm (33 ft. lbs.).
4. Lubricate and fit new 'O' rings to oil cooling pipe housing.
5. Position coolant pipe housing, fit bolts and tighten to 25 Nm (118 ft. lbs.).
6. If fitted: Secure harness in retaining clips, connect Lucars to differential lock warning switch and multiplug to neutral sensor.
7. Position breather pipes and secure 'P' clip with bolt.
8. Using new sealing washers fit breather pipe banjo bolts and tighten to 15 Nm (111 ft. lbs.).
9. Connect oil temperature sensor Lucars and reverse lamp switch multiplug.
10. Position low ratio selector cable to housing and secure with 'C' washer and clevis pin.
11. Secure cable to fuel pipes with new cable ties.
12. Raise gearbox, ensuring gear change lever is located in grommet.
13. Fit gearbox mountings and tighten bolts to 85 Nm (63 ft. lbs.).
14. Fit nuts to mountings and tighten to 48 Nm (37 ft. lbs.).
15. Remove 3 bolts securing support plate to gearbox.
16. Position clutch slave cylinder and heat shield, fit bolts and tighten to 25 Nm (18 ft. lbs.).
17. Clean hand brake back plate and mating face.
18. Position hand brake back plate, fit bolts and tighten to 75 Nm (46 ft. lbs.).
19. Clean hand brake drum.
20. Fit hand brake drum and tighten retaining screw.
21. Clean propeller shafts and mating faces.
22. Position propeller shafts, align to marks and tighten bolts to 47 Nm (35 ft. lbs.).
23. Clean exhaust silencer and tail pipe mating faces.
24. Position silencer and secure on mountings, using a new gasket align to tail pipe, fit nuts and tighten to 25 Nm (18 ft. lbs.).
25. Position rear cross member, fit bolts and tighten to 25 Nm (118 ft. lbs.).
26. Refill gearbox with oil.
27. Refill transfer gearbox oil.
28. Fit front exhaust pipe.
29. Fit gear lever extension, fit clamp bolt and tighten to 25 Nm (18 ft. lbs.).
30. Fit gear lever trim and gear change knob.
31. Connect battery earth lead.
32. Fit battery cover and cooling fan cover and secure fixings.