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MANUAL GEARBOX 5 REPAIR Separating transfer gearbox from main gearbox 50. Remove transmission assembly from hoist cradle and position safely on a bench. 51. Remove breather pipes. Discard pipe union sealing washers. 52. Remove ’Nyloc’ nut, and remove bolt, securing lever to high/low shaft. 53. Collect spacer washer. lever link. 55. Remove lower locknut from high/low operating rod. 56. Place a sling round transfer box and attach to hoist. 57. Remove nut and 4 bolts securing transfer gearbox to extension housing. 58. Withdraw transfer gearbox. Assembling transfer gearbox to main gearbox 59. Clean extension housing and transfer gearbox mating faces. 60. Ensuring loose upper dowel is fitted, hoist transfer gearbox into position. 61. Secure transfer box to extension housing. Tighten fixings to 40 Nm (30 lbf/ft). 62. Connect high/low operating rod, fit and tighten locknut. 63. Fit link to differential lock lever and secure with 2 clips 64. Align lever to high/low shaft, position washer, fit bolt and new Nyloc nut. Tighten to 2 Nm (1.5 lbf/ft). 65. Position breather pipes, secure pipe unions using new sealing washers. Tighten unions to 15 Nm (11 lbf/ft). Fitting transfer gearbox and main gearbox 66. Position transmission assembly to hoist cradle. Apply sealant to both mating faces. 68. Temporarily fit gear lever and select any gear in main gearbox to facilitate entry of gearbox input 69. Position and raise hoist, fit transmission to engine whilst keeping harness and pipes clear to 70. Secure transmission to engine. Tighten fixings to 45 Nm (33 lbf/ft). 71. Secure earth leads to RH side of transfer box. differential lock switch connectors. 73. Secure breather pipes to harness with clips. gearbox. Tighten fixings to 55 Nm (41 lbf/ft). 77. With assistance and using a body jack between chassis longitudinals, jack chassis sufficiently to |