Labor Operation Times

ENGINE.......................................................... 12

EMISSION CONTROL .................................. 17

ENGINE MANAGEMENT SYSTEM .............. 18

FUEL SYSTEM .............................................. 19

COOLING SYSTEM ...................................... 26

MANIFOLD AND EXHAUST SYSTEM .......... 30

CLUTCH ........................................................ 33

MANUAL TRANSMISSION ............................ 37

DEFENDER 90 TRANSFER GEARBOX ................................ 41

AUTOMATIC TRANSMISSION ...................... 44

DRIVE SHAFTS ............................................ 47

LABOR OPERATION REAR AXLE & FINAL DRIVE ........................ 51

TIMES FRONT AXLE & FINAL DRIVE ...................... 54

STEERING .................................................... 57
1994 MODEL YEAR ONWARDS
FRONT SUSPENSION .................................. 60

REAR SUSPENSION .................................... 64

BRAKES ........................................................ 70

BODY ............................................................ 76

SEATS............................................................ 78

HEATING AND VENTILATION ...................... 80

AIR CONDITIONING...................................... 82

WINDSHIELD WIPERS & WASHERS .......... 84

ELECTRICAL ................................................ 86
Part No.LRL 0109NAS Page Edition
2 EFFECTIVE DATE 10/97 INSTRUMENTS.............................................. 88
Published by Rover Technical
Communication.  1997 Rover Group Limited

1
2
INTRODUCTION

LABOR TIMES AND ALLOWANCES

All operation times are given in DECIMAL HOURS.
Minimum time is 0.10 hour with the exception of operations with numbers having an additional pair of
digits, e.g. 12.60.32/01.
The times listed in this publication are the result of careful study of the operations concerned. They
reflect the average time a technician should take to carry out the operation in a workshop with
average facilities efficiently. They do not reflect special familiarity.
The following items have been allowed for in operation times:
* "Wrench Time (Spanner Time)" including time taken to carry out intermediate operations, e.g.
opening and closing hood, fitting and removing fender covers, the use of jacks and lifts, draining
and refilling units cleaning.
* Time taken to drive vehicle in and out of the shop and place the vehicle in position for repair *
Repair diagnosis time. Includes use of common testers such as volt - ohmmeter, ammeter, timing light
or engine analyzer that are included in service manual or technical bulletin publications or
instructions.
* Time taken to obtain and return special tools.
* Time taken receiving instruction concerning the operation.
* Time taken to obtain appropriate parts.
* Time taken to carry out associated clerical work..
* Time taken for final test and quality checks.
No allowance has been included for inaccessibility through damage, removing extras or special
fitments, freeing seized parts, removing rusted or broken studs or bolts, or subsequent repairs after
test.
Allowances are made within the final time to change over ancillaries from the removed part or
component and to fit them onto the new part or component.
EACH OPERATION IS COMPLETE IN ITSELF UNLESS OTHERWISE STATED
e.g. Brake Master Cylinder Replace time includes allowance for bleeding brakes.
The method given in the Repair Manual describes how the time may be achieved.

DEFINITIONS
The operation "Replace"refers to the removing of an existing component or part, and fitting a new
component or part. Labor operations that indicate "replace" may not be used when a component or
part is removed for its repair and subsequent reinstallation (R&I)
Times given for "Overhaul"operations include removing the component from its installed position,
disassemble, clean and inspect all parts, rebuild the unit (assemble) with the same or new parts,
reinstall and adjust.
The term "Unit"refers to an assembly in the state in which it can be most efficiently be removed from
the vehicle.
The term "Set"applies to the complete car set of the components referred to in an operation unless
otherwise defined (i.e. brake set - all four wheels).

NUMBERING
Note:The labor operations are printed with decimal points for readability only. Do not enter
them when entering service records.
The operation numbers comprise six digits arranged in three pairs. The first pair indicates the major
assembly, the second pair the components or part of the major assembly or system and the third pair
indicates the operation and any further definition of the parts or component.

EXAMPLE
12.29.11 Cylinder head - replace
12. First digit pair (major assembly) - engine
29. Second digit pair (component) - cylinder head(s)
11. Third digit pair (specific repair or operation) - replace
Operation numbers with an additional pair of digits, e.g. 12.60.32/01, relate to operations which can
be performed with the vehicle or major system in different stages of assembly and appear
immediately following the operation to which they are related.

3
LABOR OPERATION USE
Engineers, Product Reliability and Warranty Administration Groups utilize repair or fault codes for
various reasons. For this reason, it is extremely important that correct and appropriate labor operation
numbers are selected and entered on the warranty claim.
Each claim must begin with the labor operation that caused the complaint. In the case where a failure
causes other faults, i.e. axle seal contaminates brake pad linings, the first operation number to be
entered into the warranty claim system is the labor operation number to replace the axle seal.
The labor operation to replace the brake pads is second within the same claim number. This format
allows the LRNA Warranty System to assign the appropriate failure code for Land Rover statistical
and analysis uses. This also puts the repair into perspective.
 NON - SCHEDULED TIME
If an operation does not exist for a repair, use a "00" operation. To do this, substitute the 5thand
6thcharacters with "00"e.g. 12.60.32becomes 12.60.00. Only the actual time taken to perform the
repair should be claimed. All unscheduled labor must be documented by clock times. In the event that
both scheduled and unscheduled operations are claimed for a single repair and only one clock time is
used, (no separate time punch used for unscheduled) LRNA will allow a maximum of 100% efficiency
for the entire job. The portion being claimed as unscheduled time shall be equal to the clock time less
the allowance for the scheduled labor operation.

OVERLAP
Labor operations that clearly include removal and replacement of one component to replace a
different component, as outlined in the Workshop Manual, cannot be submitted as two separate labor
operations. For example, no additional time is allowed to replace the water pump (26.50.01) if at the
same time the front timing gasket (12.65.04) is being replaced.

CUSTOMER PROBLEM ANALYSIS, SYSTEM DIAGNOSIS & REPAIR TESTING

The following are definitions of the terms used in the preceding statement:
Customer problem analysis - The process of transacting the customer’s concern, complaint, or
question to a symptom that can effectively be addressed by a technician if needed, i.e. A/C
insufficient cooling, brakes pull, engine hesitates, etc. "Customer Problem Analysis" includes those
conditions which are readily apparent to the normal senses of sight, touch, sound and smell.
"Customer Problem Analysis"is the duty of service management and/or the service advisor.
Symptom Diagnosis - The process of finding the source of a problem based on a detailed,
systematic and logical approach, i.e. finding the source of an electrical problem by following the
trouble trees and/or diagnostic charts. "Symptom Diagnosis"is the responsibility of the technician
and is included in the published labor time guide allowances.
Repair Testing - The checks, tests and measurements needed in the repair to find the cause of failure
or identify faulty parts. Examples are:
* Cleaning and inspection of all parts such as gears, clutch plates.
* Use of test equipment classified as LRNA essential tools.
* Use of common testers such as volt-ohmmeter, ammeter or timing light that are included in service
manuals and technical service publications.

4
5
6
7
12 ENGINE DEFENDER 90
(Operations include adjust ignition, fuel system or kick down
cable)
 12.13 CAMSHAFT
12.13.02 Camshaft - front/LH/each - replace ............................................... 07.50 1L1 12.13.24/01 Cam
plug/oil gallery plugs - reseal - with transmission removed ... 00.20 1A3

12.17 CONNECTING RODS & PISTONS (Includes, glaze break &

measure cylinder bores where applicable)
12.17.03 Piston assemblies - engine set - replace. ..................................... 14.10 1E1 12.17.08 Piston rings
- engine set - replace ................................................. 11.40 1E2
12.17.16 Bearings - connecting rods - engine set - replace - includes .
measure journals .......................................................................... 02.40
1C4
12.21 CRANKSHAFT

12.21.01 Pulley - crankshaft - replace ......................................................... 01.00 2G1 12.21.14 Oil seal -
crankshaft - front - replace ............................................. 01.10 1Q1 12.21.20 Oil seal - crankshaft - rear -
replace ............................................. 07.30 1Q2 12.21.20/01 Oil seal - crankshaft - rear - replace - engine
removed ................. 00.50 1Q2 12.21.33 Crankshaft - replace - includes mains bearings .............................
12.10 1C1 12.21.39 Bearings - main - engine set - replace ........................................... 12.10 1C3

12.25 CYLINDER BLOCK

12.25.01 Compression - test ......................................................................... 00.90 * 12.25.21 Bracket -
alternator mounting - replace ......................................... 00.80 7D7
9
12 ENGINE DEFENDER 90
(Operations include adjust ignition, fuel system or kick down
cable)

12.29 CYLINDER HEAD

12.29.01 Cylinder heads - remove and reinstall - including gaskets - engine .
set.
................................................................................................ 05.90 1S6
12.29.02 Cylinder head - remove & reinstall - LH/front/each - includes .
gasket ................ 04.30 1S6
..........................................................................
12.29.02/01 Cylinder head - remove & reinstall - LH/front/each - includes .
gasket - engine removed 1S6
.............................................................. 01.70
12.29.03 Cylinder head - remove and reinstall - RH/rear - includes gasket . 04.50 1S6
12.29.03/01 Cylinder head - remove and reinstall - RH/rear - includes gasket - .
engine removed .. 01.80 1S6
..........................................................................
12.29.10 Cylinder heads - engine set - replace - includes reface & grind in .
valves ................ 11.50 1F1
..........................................................................
12.29.11 Cylinder head -LH/front/each - replace - includes reface & grind in .
valves ................ 06.90 1F1
..........................................................................
 12.29.12 Cylinder head - RH/rear - replace - includes reface & grind in .
valves ................ 07.10 1F1
..........................................................................
12.29.29 Rocker shaft assembly - LH/front/each - replace . .......................... 01.30 1H6 12.29.30 Rocker
shaft assembly - RH/rear - replace . .................................. 01.20 1H6 12.29.31 Push rods - set - LH -
replace. . ...................................................... 01.30 1H4 12.29.32 Push rods - set - RH - replace. .
.................................................... 01.30 1H4 12.29.39 Gaskets - covers - camshaft/valve - engine set -
replace . ............ 01.80 1S1 12.29.40 Gasket - cover - camshaft/valve - LH/front/each - replace . ............
01.00 1S1 12.29.41 Gasket - cover - camshaft/valve - RH/rear - replace . .................... 01.00 1S1 12.29.49
Rocker shaft assembly - LH/front/each - overhaul . ........................ 01.60 1H6 12.29.50 Rocker shaft
assembly - RH/rear - overhaul . ................................ 01.50 1H6 12.29.54 Rocker shaft assembly - engine
set - replace . .............................. 02.20 1H6 12.29.55 Rocker shaft assembly - engine set - overhaul .
............................ 02.90 1H6 12.29.57 Tappets/cam followers - engine set - replace . ..............................
04.20 1H2
12.29.58 Valve guide - one only - cylinder head - front/LH - replace - .
includes reface seat & grind in valve ............................................ 04.90 1F3
12.29.58/01 Valve guide - extra each - cylinder head - front/LH - replace - .
includes reface seat & grind in valve ............................................ 00.50 1F3
12.29.60 Pushrods - engine set - replace . .................................................... 02.40 1H4 12.29.61 Valve
guides - engine set - replace - includes reface seats & grind
.
in valves .............. 14.60 1F3
..........................................................................
12.29.62 Valves - engine set - replace - includes reface seats, grind in .
valves & replace head gaskets .................................................... 10.90 *
12.29.82 Valves - LH/front/each bank - head set - replace - includes reface .
seats, grind in valves & replace head gasket .............................. 06.80 *
12.29.83 Valves - RH/rear bank - head set - replace - includes reface seats, .
grind in valves & replace head gasket .......................................... 07.00 *
G - LOOSE/SEAK SYNCHROMESH DIFFICULT ENGAGEMENT Q -
H - CORRODED/PLATING FADED/STAINED/DISCOLOURED R -
FAILURE FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
A - WRONGLY ADJUSTED 10 - INACCURATE/SLIPPING
J - WORN/STRETCHED V - BULB/LIGHT UNIT FAILURE W -
B - POROUS/ADRIFT
K - NOISY/CHAFED VIBRATION/OUT OF BALANCE X -
C - BAD FIT
L - JUDDER/POOR CONNECTION M BRAKE PULL/SURFACE DAMAGE Z
D - BROKEN
- BODY/COOLANT LEAKS/BURNT N - INOPERATIVE
E - CRACKED/SPLIT/CUT
- LEAKS - NOT COOLANT LOSS P -
F - SEIZED/STIFF
11
12 ENGINE DEFENDER 90
(Operations include adjust ignition, fuel system or kick down
cable)

12.29 CYLINDER HEAD

12.29.88 Valve guides - LH/front/each bank - set - replace . ........................ 08.70 1F3 12.29.89 Valve
guides - RH/rear bank - set - replace . .................................. 08.80 1F3 12.29.90 Oil seal - valve stem - inlet
- engine set - replace . ........................ 07.80 1Q3 12.29.93 Oil seal - valve stem - inlet & exhaust - engine
set - replace . ........ 09.60 1Q3
12.29.98 Valve guide - one only - cylinder head - RH/rear - replace - .
includes reface seat & grind in valve ............................................ 05.10 1F3
12.29.98/01 Valve guide - extra each - cylinder head - RH/rear - replace - .
includes reface seat & grind in valve ............................................ 00.50 1F3
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

12
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
13
12 ENGINE DEFENDER 90
(Operations include adjust ignition, fuel system or kick down
cable)

12.41 ENGINE ASSEMBLY

12.41.01 Engine & ancilliaries - replace . ...................................................... 07.50 * 12.41.02 Stripped
engine/long block - remove engine, change over ancillary
.
equipment & reinstall 10.40 *
....................................................................
12.41.03 Short block (block with crank and pistons) - replace . .................... 12.90 *

12.45 ENGINE MOUNTINGS

12.45.01 Mounting - front - LH - replace . ...................................................... 00.50 5C1 12.45.03 Mounting
- front - RH - replace . .................................................... 00.50 5C1 12.45.04 Mountings - front - set -
replace . .................................................... 00.50 5C1 12.45.07 Mounting - rear - LH - replace. .
...................................................... 00.60 5C1 12.45.09 Mounting - rear - RH - replace. .
.................................................... 00.60 5C1 12.45.10 Mountings - rear - set - replace .
.................................................... 01.00 5C1
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

14
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
15
12 ENGINE DEFENDER 90
(Operations include adjust ignition, fuel system or kick down
cable)

12.53 FLYWHEEL & DRIVE PLATE

12.53.13 Drive plate - automatic - replace . .................................................. 07.00 4A5 12.53.13/01 Drive
plate - automatic - replace - with transmission removed . .... 00.20 4A5 12.53.19 Ring gear - starter -
replace . .......................................................... 07.00 1C7

12.60 LUBRICATION SYSTEM

12.60.04 Filter - oil - replace . ........................................................................ 00.30 2A6 12.60.20 Strainer -
oil pick up - replace . ...................................................... 01.20 2A2 12.60.26 Pump - oil - replace. .
...................................................................... 03.30 2A1 12.60.38 Oil pan to engine - reseal or fit new
gasket . .................................. 01.10 1S5 12.60.38/01 Oil pan to engine - reseal or fit new gasket - with
engine removed . 00.60 1S5 12.60.44 Pan - oil - replace . ..........................................................................
01.10 1N1 12.60.50 Switch - oil pressure - replace . ...................................................... 00.30 7V4 12.60.56
Valve - oil pressure relief - replace . .............................................. 03.30 2A3 12.60.74 Hose(s) - feed - oil
cooler - replace . .............................................. 01.00 2A9 12.60.76 Hose - return - oil cooler - replace .
................................................ 01.00 2A9
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

16
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
17
12 ENGINE DEFENDER 90
(Operations include adjust ignition, fuel system or kick down
cable)

12.65 TIMING GEARS, CHAINS, TENSIONERS & GUIDES

12.65.01 Cover - timing gears - replace. . .................................................... 03.30 1N6 12.65.04 Gasket -
timing gear cover - replace . ............................................ 03.20 1S2 12.65.04/01 Gasket - timing gear cover
- replace - with unit removed . ............ 01.60 1S2 12.65.06 Oil seal & gasket - timing gear cover - replace .
............................ 03.20 1S2 12.65.12 Timing belt/chain & gears - replace . ..............................................
03.50 1K5
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

18
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
19
17 EMISSION CONTROL DEFENDER 90

17.15 EVAPORATIVE LOSS CONTROL SYSTEMS

17.15.13 Charcoal canister - replace . .......................................................... 00.50 2R1 17.15.19 Expansion
tank/vapour seperator - replace . .................................. 00.50 2R7

17.50 CATALYTIC CONVERTOR

17.50.09 Catalytic converter - down pipe - LH/each - replace . .................... 01.20 2S4
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

20
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
21
18 ENGINE MANAGEMENT SYSTEM DEFENDER 90

18.20 IGNITION SYSTEM

18.20.02 Spark plugs - replace (See normal wear limits) . ............................ 00.70 7A9 18.20.11 Wire -
spark plug - engine set - replace. . ...................................... 00.40 7B1 18.20.45 Ignition coils - multiple - set
- replace . ............................................ 00.70 7A8

18.30 SENSORS, SWITCHES, RELAYS & VALVES

18.30.01 Engine control module (ECM) - combined ignition & fuel - replace . 00.30 7G1 18.30.09 Sensor -
intake air temperature (IAT) - replace . ............................ 00.20 2F6 18.30.10 Sensor - engine coolant
temperature (ECTS) - replace . ................ 00.30 7U3 18.30.12 Sensor - crankshaft position (CKP) - replace
. ................................ 00.40 7E7 18.30.24 Sensor - camshaft position (CMP) - replace .
................................ 00.30 7E8 18.30.28 Sensor - knock(KS) - LH/each - replace . ......................................
00.40 7A0 18.30.30 Sensor - knock (KS) - RH - replace . .............................................. 00.40 7G4 18.30.71
Relay module - replace . ................................................................ 00.30 7W4
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

22
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
23
19 FUEL SYSTEM DEFENDER 90

19.10 AIR CLEANERS & HOSES

19.10.01 Air cleaner(s) - replace . ................................................................ 00.40 2F1 19.10.10 Element -
air cleaner - replace . ...................................................... 00.30 2F4 19.10.17 Hose - intake - single -
replace . .................................................... 00.20 2F2

19.20 CONTROLS
19.20.01 Pedal - throttle - replace . .............................................................. 00.50 2K7 19.20.06 Cable -
throttle - replace . .............................................................. 00.30 2K5 19.20.23 Return spring - throttle pedal
- replace. . ........................................ 00.50 2K6

19.22 ELECTRONIC FUEL DISTRIBUTION EQUIPMENT

19.22.08 Sensor - engine fuel temperature (EFTS) - replace . ...................... 00.20 7G9 19.22.09 Switch -
inertia - fuel cut off - replace . ............................................ 00.20 6P2 19.22.16 Sensor - heated oxygen
(HO2S) - front/LH/each - replace . .......... 00.30 2T6 19.22.17 Sensor - heated oxygen (H02S) - rear/RH -
replace . .................... 00.30 2T5 19.22.25 Sensor - mass air flow (MAFS) - replace .
...................................... 00.20 7W2 19.22.46 Plenum chamber - replace .
............................................................ 01.10 2R5 19.22.49 Sensor - throttle position (TPS) - replace
(includes adjust). . ........ 00.20 7G5 19.22.54 Valve - (IACV)idle air control (stepper motor) - replace .
................ 00.30 7W1

19.25 FUEL FILTERS

19.25.02 Filter - main - replace . .................................................................... 00.30 2R3
 B - POROUS/ADRIFT - INOPERATIVE
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

24
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
A - WRONGLY ADJUSTED
25
19 FUEL SYSTEM DEFENDER 90

19.45 FUEL PUMP

19.45.06 Regulator - pressure - replace. . .................................................... 00.70 2R6 19.45.08 Pump -
replace . ............................................................................ 01.40 7F9

19.50 FUEL SYSTEM

19.50.02 Fuel system - depressurise . .......................................................... 00.20 *

19.55 FUEL TANK

19.55.02 Tank - drain fuel . ............................................................................ 00.40 * 19.55.07 Filler neck -
replace . ...................................................................... 00.50 2Q0 19.55.08 Cap - fuel filler - replace .
................................................................ 00.10 9M3 19.55.10 Sealing ring - fuel filler cap - replace. .
............................................ 00.20 19.55.12 Hose - filler neck to tank - replace .
................................................ 00.50 2Q0 19.55.26 Tank - fuel - rear - replace .
............................................................ 01.50 2Q8

19.60 INJECTORS
19.60.04 Fuel rail - replace . .......................................................................... 02.50 2N5 19.60.10 Injector -
one only - replace . .......................................................... 01.80 2P2 19.60.12 Injectors - set - replace .
................................................................ 02.30 2P2

19.70 VENTURI/AIR INTAKE

19.70.04 Housing - assembly - ram pipe - replace . ...................................... 01.10
 B - POROUS/ADRIFT - INOPERATIVE
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

26
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
A - WRONGLY ADJUSTED
27
19 FUEL SYSTEM DEFENDER 90

19.80 ROUGH ROAD DETECTION SYSTEM

19.80.01 Sensor - wheel speed - front - each - replace . .............................. 00.90
19.80.02 Sensor - wheel speed - rear - each - replace . ................................ 00.90
19.80.03 Electronic Control Module (ECM) - replace . .................................. 00.30

19.90 DIAGNOSIS
(Operations are based on the procedures in the shop manual,
trouble shooting manuals and/or using TestBook)
19.90.06/01 Fuel system pressure - test . .......................................................... 00.50 *
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

28
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
29
26 COOLING SYSTEM DEFENDER 90
(Operations include drain, refill, bleed system and pressure
test where necessary)

26.10 COOLANT & SYSTEM

26.10.01 Cooling system drain, flush and refill . ............................................ 00.80 - 26.10.07 System -
pressure test . .................................................................. 00.30 -

26.15 EXPANSION TANKS

26.15.01 Tank - replace . .............................................................................. 00.30 2C7

26.25 FANS
26.25.03 Pulley - water pump - replace . ...................................................... 00.70 2H8 26.25.06 Fan blades
- LH/single - replace . .................................................. 00.40 2C1 26.25.11 Cowl/shroud - fan - replace .
.......................................................... 00.30 2C1 26.25.19 Coupling unit - viscous fan - replace .
............................................ 00.40 2C2
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

30
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
31
26 COOLING SYSTEM DEFENDER 90
(Operations include drain, refill, bleed system and pressure
test where necessary)

26.30 HOSES & PIPES

26.30.01 Hose - top - radiator - replace . ...................................................... 00.30 2E1 26.30.04 Hose -
radiator to throttle housing - replace . .................................. 00.90 2E9 26.30.07 Hose - bottom - radiator -
replace . ................................................ 01.10 2E2 26.30.29 Hose - manifold to heater pipe - replace. .
...................................... 00.20 2E4 26.30.30 Hose - manifold to heater valve/heater - replace .
.......................... 00.20 2E4 26.30.33 Hose - radiator to expansion tank - replace . ..................................
00.20 2E6 26.30.44 Hose - heater to return pipe - replace . .......................................... 00.20 2E5 26.30.50
Hose - manifold to throttle housing - replace . ................................ 00.90 2E9

26.40 RADIATOR
26.40.01 Radiator assembly - replace . ........................................................ 01.50 2C5

26.45 THERMOSTAT
26.45.01 Thermostat - replace. . .................................................................... 00.90 2C4 26.45.06 Gasket -
thermostat housing - LH/single - replace . ........................ 00.90 2U8 26.45.09 Thermostat - test - includes
install new thermostat if necessary . .. 01.10 2C4

26.50 WATER PUMP

26.50.01 Pump - water - replace . ................................................................ 01.10 2C3
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

32
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE
A - WRONGLY ADJUSTED
33
30 MANIFOLD & EXHAUST SYSTEM DEFENDER 90

30.10 EXHAUST SYSTEM (See 17.50 for three way catalyst)

30.10.01 Exhaust system - replace . ............................................................ 01.20 * 30.10.09 Front pipe -
replace. . ...................................................................... 01.20 2S3 30.10.11 Intermediate pipe &/or muffler -
replace. . ...................................... 00.50 2S5 30.10.22 Tail pipe & muffler - replace .
.......................................................... 00.40 2S9 30.10.28 Heat shield - front pipe - replace .
.................................................. 00.20 2T2

30.15 MANIFOLDS
30.15.02 Manifold - air intake - LH/front/single - replace . ............................ 02.60 2S1 30.15.08 Gasket(s) -
air intake manifold - LH/each - replace . ...................... 02.60 2U1
30.15.08/01 Gasket(s) - air intake manifold - LH/each - replace - with engine .
removed .............. 00.60 2U1
..........................................................................
30.15.10 Manifold - exhaust - LH/front/single - replace . .............................. 01.20 2S1 30.15.11 Manifold -
exhaust - RH/rear - replace . .......................................... 01.10 2S1 30.15.16 Gasket(s) - exhaust manifold -
RH/rear - replace . ........................ 01.10 2U3 30.15.16/01 Gasket(s) - exhaust manifold - RH/rear - replace
- engine removed. 00.30 2U3 30.15.17 Gasket(s) - exhaust manifold - LH/front/single - replace . ..............
01.20 2U3
30.15.17/01 Gasket(s) - exhaust manifold - LH/front/single - replace - engine .
removed .............. 00.30 2U3
..........................................................................

30.20 MOUNTINGS
30.20.02 Mounting rubber - front - replace . .................................................. 00.10 2T1 30.20.03 Mounting
rubber - center - replace . .............................................. 00.20 2T1 30.20.04 Mounting rubber - rear - each -
replace . ........................................ 00.20 2T7 30.20.06 Mountings - set - replace .
.............................................................. 00.30 2T1
 B - POROUS/ADRIFT V - BULB/LIGHT UNIT FAILURE W -
C - BAD FIT VIBRATION/OUT OF BALANCE X -
D - BROKEN BRAKE PULL/SURFACE DAMAGE Z
E - CRACKED/SPLIT/CUT - INOPERATIVE
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

34
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
A - WRONGLY ADJUSTED
35
33 CLUTCH DEFENDER 90
(Operations include bleeding hydraulic system where
necessary)

33.10 CLUTCH ASSEMBLY

33.10.01 Clutch assembly - replace . ............................................................ 05.70 * 33.10.01/01 Clutch
assembly - replace - transmission removed . ...................... 00.20 * 33.10.02 Clutch disc - replace .
.................................................................... 05.70 3A2 33.10.07 Pressure plate, clutch disc & throw out
bearing - replace . ............ 05.75 *

33.15 HYDRAULIC SYSTEM

33.15.01 Hydraulic system - bleed . .............................................................. 00.20 *

33.20 MASTER CYLINDER

33.20.01 Cylinder - master - replace . .......................................................... 01.55 3B4 33.20.07 Cylinder -
master - overhaul . ........................................................ 01.75 3B4

33.25 MECHANICAL LINKAGE & RELEASE

33.25.12 Bearing - throw out - replace . ........................................................ 04.70 3A3 33.25.13 Arm -
clutch throw out - replace . .................................................... 04.80 3A6

33.30 PEDAL ASSEMBLIES

33.30.02 Pedal - clutch - replace . ................................................................ 01.75 3B6 33.30.08 Pad cover -
clutch pedal - replace . ................................................ 00.25 3B6

33.35 SLAVE CYLINDER

33.35.01 Cylinder - slave - replace . .............................................................. 00.45 3B5 33.35.07 Cylinder -
slave - overhaul . ............................................................ 00.55 3B5
 B - POROUS/ADRIFT V - BULB/LIGHT UNIT FAILURE W -
C - BAD FIT VIBRATION/OUT OF BALANCE X -
D - BROKEN BRAKE PULL/SURFACE DAMAGE Z
E - CRACKED/SPLIT/CUT - INOPERATIVE
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

36
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
A - WRONGLY ADJUSTED
37
37 MANUAL TRANSMISSION DEFENDER 90

37.12 COVERS, CASE & EXTENSIONS

37.12.01 Extension - rear - replace . ............................................................ 06.75 3D8
37.12.01/01 Extension - rear - remove, reseal & reinstall (includes replace oil .
seal) ..................... 07.85 *
.........................................................................
37.12.07 Housing - clutch/bell - replace . ...................................................... 06.00 3D2 37.12.09 Cover -
bottom - replace . .............................................................. 00.50 3D3 37.12.33 Cover - front - replace .
.................................................................. 06.25 3D2 37.12.33/01 Cover - front - remove, reseal & reinstall
(includes replace oil seal). 06.20 3D2 37.12.35 Pipe - oil pump feed - replace. .
...................................................... 07.85 3F2 37.12.38 Filter - transmission oil - replace .
.................................................. 06.75
37.12.40 Main case - replace . ...................................................................... 06.95 3D1 37.12.41 Main case
- reseal or replace gasket . ............................................ 06.95 3D1 37.12.47 Pump - oil - replace. .
...................................................................... 06.95 3H0 37.12.48 Pump - oil - overhaul .
.................................................................... 08.15 3H0

37.16 GEARSHIFT, CONTROLS & SELECTORS

37.16.02 Bias spring - gear shift lever - replace. . ........................................ 01.60 3J9 37.16.04 Lever -
gear shift - replace . ............................................................ 01.75 3J1 37.16.09 Ball socket - gear shift lever
- replace. . .......................................... 01.80 3J2 37.16.10 Yoke assembly - selector shaft - replace. .
.................................... 01.70 3J8 37.16.11 Knob - gear shift lever - replace .
.................................................... 00.30 3J1 37.16.14 Lever - upper - gear shift - replace .
.............................................. 00.30 3J1 37.16.15 Lever - lower - gear shift - replace .
................................................ 01.75 3J1 37.16.26 Bias spring - gear shift lever - adjust .
............................................ 01.50 3J9 37.16.27 Cover - bias spring - replace .
........................................................ 01.40 3J9 37.16.29 Gasket - selector mechanism housing - replace .
.......................... 01.80 3R9 37.16.37 Mechanism & housing - gear selector - replace . ............................
02.00 *
37.16.37/01 Housing - gear selector mechanism - remove, reseal & reinstall . .. 01.65 * 37.16.40
Mechanism & housing - gear selector - overhaul . .......................... 02.00 * 37.16.45 Forks - selector shaft -
replace . .................................................... 08.35 3M5 37.16.55 Selector fork - 5th/reverse speed - replace .
.................................. 07.55 3M3 37.16.69 Gate - selector - replace .
.............................................................. 06.85 37.16.73 Stop/cam - reverse gear - replace .
................................................ 01.85
 B - POROUS/ADRIFT - LEAKS - NOT COOLANT LOSS P -
C - BAD FIT DIFFICULT ENGAGEMENT Q -
D - BROKEN FADED/STAINED/DISCOLOURED R -
E - CRACKED/SPLIT/CUT FACTORY DAMAGE
F - SEIZED/STIFF S - OPEN CIRCUIT/BLOCKED T -
G - LOOSE/SEAK SYNCHROMESH SHORT CIRCUIT/THREAD DAMAGE U
H - CORRODED/PLATING - INACCURATE/SLIPPING
FAILURE V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
38 - INOPERATIVE
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
A - WRONGLY ADJUSTED - BODY/COOLANT LEAKS/BURNT N
39
37 MANUAL TRANSMISSION DEFENDER 90

37.20 TRANSMISSION ASSEMBLY

37.20.02 Transmission - replace . ................................................................ 06.05 * 37.20.02/99
Transmission - remove for access & reinstall . .............................. 04.50 * 37.20.04 Transmission assembly
- overhaul - includes final drive . .............. 10.00 * 37.20.06 Transmission assembly - overhaul (includes
transfer gearbox). . .. 20.60 * 37.20.07 Synchronizer assemblies - replace . ..............................................
08.75 * 37.20.13 Shaft - reverse idler gear - replace . .............................................. 08.65 3H4
37.20.15 Gear - reverse idler - replace. . ...................................................... 08.65 3C1 37.20.16 Shaft -
input - replace . .................................................................. 08.55 3H1 37.20.17 Bearing(s) - input shaft -
replace . .................................................. 08.55 3H5 37.20.19 Countershaft - replace .
.................................................................. 08.65 3H3 37.20.23 Synchronizer assembly - 3rd/4th gear -
replace . .......................... 08.75
37.20.25 Shaft - output - replace . ................................................................ 08.75 3H2 37.20.27 Bearings -
countershaft - replace . .................................................. 08.65 3H7 37.20.36 Gear(s) - 5th speed - replace .
........................................................ 07.55 3E6 37.20.38 Synchronizer assembly - 5th/reverse - replace .
............................ 08.75 3C5 37.20.39 Synchronizer assembly 5th/reverse - overhaul . ............................
08.80 3G5 37.20.43 5th gear - layshaft - replace . .......................................................... 08.35 3H3 37.20.49
Synchronizer - 1st/2nd speed - replace . ........................................ 08.55 *
37.20.51 Main transmission and transfer gearbox assembly - replace . ........ 06.30 * 37.20.55 Bearing -
main shaft rear support - replace . .................................. 08.35 3H6 37.20.56 Retaining collars - mainshaft -
5th gear - replace. . ........................ 08.05 37.20.57 Reverse gear - mainshaft - replace .
.............................................. 08.80 3E7 37.20.58 Bearing - layshaft rear support - replace .
...................................... 08.25 3H7 37.20.59 Reverse gear - layshaft - replace .
.................................................. 08.75 3E7 37.20.60 Baffle plate - reverse gear - replace .
............................................ 07.90
 B - POROUS/ADRIFT V - BULB/LIGHT UNIT FAILURE W -
C - BAD FIT VIBRATION/OUT OF BALANCE X -
D - BROKEN BRAKE PULL/SURFACE DAMAGE Z
E - CRACKED/SPLIT/CUT - INOPERATIVE
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

40
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
A - WRONGLY ADJUSTED
41
37 MANUAL TRANSMISSION DEFENDER 90

37.23 OIL SEALS

37.23.01 Oil seal - output shaft - replace . .................................................... 06.05 3R7 37.23.01/01 Oil seal
- output shaft - replace - transfer gearbox removed. . ........ 00.20 3R7 37.23.03 Collar - oil seal - mainshaft -
replace . ............................................ 05.25 3S3 37.23.06 Oil seal - input shaft - replace .
...................................................... 06.25 3R6 37.23.06/01 Oil seal - input shaft - replace - transmission
removed . ................ 00.40 3R6 37.23.16 Transmission - reseal, fit new oil seals and ’O’ ring(s) .
.................. 11.25 *
37.23.16/01 Transmission - reseal, fit new oil seals and ’O’ ring(s) - .
transmission removed. .................................................................. 03.00 *

37.24 LUBRICATION

37.24.02 Cooler - transmission oil/fluid - replace . ........................................ 00.45 *

37.24.03 Pipe/hose - oil/fluid cooler feed - radiator to front oil cooler - .
replace ................ 01.55 3F2
..........................................................................
37.24.04 Pipe/hose - oil/fluid cooler return - from front oil cooler - replace . .. 01.55 3F2 37.24.05 Pipe/hose
- oil/fluid cooler feed - transmission to radiator - replace. 00.95 3F2 37.24.06 Pipe/hose - oil/fluid cooler
return - to transmission - replace . ........ 00.95 3F2 37.24.07 Thermostat - transmission oil cooler - replace .
.............................. 01.20 3S9 37.24.08 Seals - thermostat housing - transmission oil cooler - replace . ....
01.15 3Z7

37.25 SPEEDOMETER DRIVE

37.25.05 Pinion - speedometer drive - replace . ............................................ 00.35 3E9

37.27 SWITCHES
37.27.01 Switch - back-up light - replace . .................................................... 01.00 7H1 37.27.03 Switch -
hi-lo warning - replace . .................................................... 00.80 3T9
 B - POROUS/ADRIFT - INACCURATE/SLIPPING
C - BAD FIT V - BULB/LIGHT UNIT FAILURE W -
D - BROKEN VIBRATION/OUT OF BALANCE X -
E - CRACKED/SPLIT/CUT BRAKE PULL/SURFACE DAMAGE Z
F - SEIZED/STIFF - INOPERATIVE
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

42
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
A - WRONGLY ADJUSTED
43
41 TRANSFER GEARBOX DEFENDER 90

41.20 TRANSFER GEARBOX

41.20.05 Bottom cover - transfer gearbox - replace . .................................... 00.60 41.20.06 Gasket -
bottom cover - transfer gearbox - replace. . .................... 00.60 41.20.08 Bearing - front output shaft -
replace . ............................................ 05.00 3N3 41.20.09 Output shaft - front - replace. .
........................................................ 05.00 3H2 41.20.10 Intermediate gear assembly - replace .
.......................................... 06.70 41.20.13 Differential assembly - replace .
.................................................... 08.60 3L9 41.20.14 Drive flange - rear output shaft - replace .
...................................... 00.90 3N5 41.20.15 Drive flange - front output shaft - replace .
...................................... 00.70 3N5 41.20.16 Differential assembly - overhaul .
.................................................. 09.90 3L9 41.20.17 Bearings - differential assembly - replace .
.................................... 08.60 41.20.18 Output shaft - rear - replace . ..........................................................
01.40 3N2 41.20.19 Bearing - rear output shaft - replace . ............................................ 01.40 3N2 41.20.21
Intermediate shaft rear bearing - replace . ...................................... 01.00 3N1 41.20.22 Gear - drive -
intermediate shaft - replace . .................................... 01.00 41.20.23 Dog clutch - differential lock - replace.
. .......................................... 04.70 3L8 41.20.25 Transfer gearbox - replace .
.......................................................... 05.10 * 41.20.25/99 Transfer gearbox - remove for access & reinstall .
........................ 05.30 * 41.20.28 Transfer gearbox - overhaul . ........................................................ 12.30 *
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

44
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
45
41 TRANSFER GEARBOX DEFENDER 90

41.20 TRANSFER GEARBOX

41.20.30 Gasket - rear cover plate - replace . .............................................. 00.40 3R4 41.20.33 Switch -
differential lock actuator - adjust . .................................... 00.90 41.20.34 Switch - differential lock actuator -
replace . .................................. 01.00 41.20.40 Housing - selector lever - replace .
................................................ 01.00 3W8 41.20.41 Housing - selector lever - overhaul .
.............................................. 01.80 3W8 41.20.44 Gasket - hi-lo selector housing - replace .
...................................... 01.40 3R9 41.20.46 Linkage/cable - hi-lo selector - adjust .
.......................................... 00.90 3W8 41.20.47 Fork - hi-lo selector - replace .
........................................................ 07.20 3W8 41.20.48 Gasket - input gear support plate - replace .
.................................. 00.40 41.20.49 Input gear/bearings - replace . ........................................................
07.10 8H5 41.20.50 Oil seal - input shaft - replace . ...................................................... 05.30 3R6
41.20.50/01 Oil seal - input shaft - replace - transfer gearbox removed . .......... 00.10 3R6 41.20.51 Oil
seal(s) - front output shaft - replace . ........................................ 00.60 3R7 41.20.52 Gasket - front output
shaft housing - replace . ................................ 04.20 3R7 41.20.54 Oil seal(s) - rear output shaft - replace .
........................................ 00.90 3R7 41.20.55 Gasket - rear output shaft housing - replace .
................................ 01.10 3R7 41.20.58 Hi-lo selector hub & sleeve assembly - replace . ............................
07.70 3W8 41.20.60 Input gear/bearing - replace . .......................................................... 07.10 3H5
41.20.60/01 Input gear/bearing - replace - with unit removed . .......................... 01.40 3H5 41.20.61 High
gear - central differential - replace . ........................................ 07.50 41.20.62 Low gear - centre differential -
replace. . ........................................ 07.70 41.20.63 Solenoid - hi-lo gearshift interlock - replace .
.................................. 01.00 3T9 41.20.64 Switch - audible alarm - gearshift neutral - replace .
...................... 00.90 3T0 41.20.65 Knob - hi-lo selector lever - replace . .............................................. 00.20
3L3
 B - POROUS/ADRIFT VIBRATION/OUT OF BALANCE X -
C - BAD FIT BRAKE PULL/SURFACE DAMAGE Z
D - BROKEN - INOPERATIVE
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

46
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING

A - WRONGLY ADJUSTED V - BULB/LIGHT UNIT FAILURE W -

47
44 AUTOMATIC TRANSMISSION DEFENDER 90 (Operations include
adjustments to cables where necessary)

44.15 CONTROLS & LINKAGE

44.15.01 Cable/control - downshift - replace - includes adjustment . ............ 02.70 4F5 44.15.04 Lever -
gearshift selector assembly - replace . .............................. 01.40 4F1 44.15.07 Knob - gearshift lever -
replace . .................................................... 00.20 4F1 44.15.08 Rod/cable assembly - gearshift - replace. .
.................................... 01.50 4F3 44.15.10 Indicator - gearshift - replace .
........................................................ 00.60 4F8 44.15.19 Switch - starter inhibitor - replace .
................................................ 00.50 7H2 44.15.20 Gearshift shaft, cams & stop plate - replace .
................................ 03.00 4F2 44.15.34 Oil seal - gearshift shaft - replace . ................................................
00.40 4H8 44.15.37 Relay(s) - gearshift interlock - replace. . ........................................ 00.10 4B3 44.15.38
Relay(s) - gearshift neutral - replace . ............................................ 00.10 4B4
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

48
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
49
44 AUTOMATIC TRANSMISSION DEFENDER 90 (Operations include
adjustments to cables where necessary)

44.17 CONVERTER, HOUSING & PRIMARY DRIVE

44.17.07 Converter assembly - replace . ...................................................... 07.20 4A4 44.17.11 Oil seal -
converter - replace. . ........................................................ 07.20 4H1

44.20 TRANSMISSION ASSEMBLY & CASINGS

44.20.02 Transmission & converter - replace . .............................................. 07.60 * 44.20.04/99
Transmission/converter & transfer gearbox assembly - remove for
.
access and reinstall 07.00 *
......................................................................
44.20.11 Gasket - intermediate plate - replace . ............................................ 07.50 * 44.20.18 Oil seal - rear
extension housing - replace . .................................. 05.30 4J5 44.20.19 Gasket - rear extension housing -
replace . .................................... 05.80 4J8
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

50
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
51
44 AUTOMATIC TRANSMISSION DEFENDER 90 (Operations include
adjustments to cables where necessary)

44.22 GOVERNOR
44.22.01 Governor assembly - replace . ........................................................ 06.00 4E1 44.22.04 Governor
assembly - overhaul . ...................................................... 06.20 4E1

44.24 LUBRICATION SYSTEM

44.24.01 Tube - fluid filler - replace . ............................................................ 00.70 4B8 44.24.02 Lubrication
system - drain & refill . .................................................. 00.60 * 44.24.04 Pan - fluid - replace .
...................................................................... 02.10 4A0 44.24.05 Gasket- oil/fluid pan - replace .
...................................................... 02.10 4H7 44.24.07 Filter - fluid - replace .
.................................................................... 02.20 44.24.10 Cooler - oil/fluid - replace .
.............................................................. 01.10 4B9 44.24.13 Hose - supply - fluid cooler - replace .
............................................ 00.80 4B0 44.24.14 Hose - return - fluid cooler - replace .
............................................ 00.80 4B0 44.24.15 Hoses/pipes - oil/fluid cooler - set - replace .
.................................. 00.90 4B0

44.28 PARKING BRAKE/PARK LOCK

44.28.07 Parking brake pawl assembly/park lock mechanism - replace . .... 05.80 4D7

44.30 PRESSURE & ADJUSTMENT CHECKS

44.30.02 Cable/linkage - downshift control - check & adjust. . ...................... 00.20 4F5 44.30.04 Cable/rod -
 gearshift - check & adjust . .......................................... 00.30 4F3 44.30.13 Stall test. .
...................................................................................... 00.60 *

44.32 PUMPS
44.32.01 Pump - main - replace . .................................................................. 08.20 4A7 44.32.07 Oil seal -
main pump - replace. . .................................................... 07.20 4H2

44.40 VALVE BODIES

44.40.01 Valve body assembly - replace . .................................................... 02.50 4C9

44.90 DIAGNOSIS
(Operations are based on the procedures in the shop manual,
trouble shooting manuals and/or using TestBook)
44.90.01/01 Automatic transmission test procedure (includes pressure test) . .. 00.70
B - POROUS/ADRIFT - BODY/COOLANT LEAKS/BURNT N
C - BAD FIT - LEAKS - NOT COOLANT LOSS P -
D - BROKEN DIFFICULT ENGAGEMENT Q -
E - CRACKED/SPLIT/CUT FADED/STAINED/DISCOLOURED R -
F - SEIZED/STIFF FACTORY DAMAGE
G - LOOSE/SEAK SYNCHROMESH S - OPEN CIRCUIT/BLOCKED T -
H - CORRODED/PLATING SHORT CIRCUIT/THREAD DAMAGE U
FAILURE - INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
52 BRAKE PULL/SURFACE DAMAGE Z
J - WORN/STRETCHED - INOPERATIVE
K - NOISY/CHAFED
A - WRONGLY ADJUSTED
L - JUDDER/POOR CONNECTION M
53
47 DRIVE SHAFTS DEFENDER 90

47.15 PROPELLER SHAFT

47.15.02 Propeller shaft - front - replace . .................................................... 00.70 4K1 47.15.03 Propeller
shaft - rear - replace . ...................................................... 00.70 4K1 47.15.11 Universal joint(s) - propeller
shaft - front - replace . ........................ 01.80 * 47.15.12 Universal joint(s) - propeller shaft - rear - replace .
........................ 01.80 *
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

54
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
55
51 REAR AXLE & FINAL DRIVE DEFENDER 90

51.10 AXLE (HALF) SHAFTS

51.10.01 Half shaft - LH/each - replace. . ...................................................... 00.40 4L5 51.10.03 Half shafts
- both - replace . ............................................................ 00.70 4L5

51.15 DIFFERENTIAL ASSEMBLY

51.15.01 Differential assembly - replace . .................................................... 01.50 *

51.20 OIL SEALS & GASKETS

51.20.01 Oil seal - pinion - replace . .............................................................. 00.60 4S1

51.25 REAR AXLE & FINAL DRIVE UNIT

51.25.01 Axle assembly - replace . ................................................................ 02.50 * 51.25.04 Casing -
replace . ............................................................................ 03.80 4N1
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

56
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
57
54 FRONT AXLE & FINAL DRIVE DEFENDER 90

54.10 DIFFERENTIAL ASSEMBLY

54.10.01 Differential assembly - replace . .................................................... 03.40 * 54.10.20 Oil seal -
pinion - replace . .............................................................. 00.60 4S5

54.15 FRONT AXLE ASSEMBLY

54.15.01 Axle assembly - replace . ................................................................ 02.30 * 54.15.03 Casing -
replace . ............................................................................ 03.30 4N1 54.15.04 Oil seal - axle case -
replace. . ...................................................... 01.00 4S6 54.15.06 Oil seals - axle case - both sides - replace
. .................................. 01.70 4S6

54.20 SHAFTS
54.20.07 Half shaft - LH/each - replace. . ...................................................... 01.30 4L1 54.20.08 Half shaft
- both - replace . ............................................................ 02.50 4L1 54.20.11 Half shaft - RH - replace .
.............................................................. 01.30 4L1 54.20.12 End float - axle shaft - LH/each - check and
adjust . ...................... 00.40 *
54.20.13 End float - axle shaft - both - check and adjust . ............................ 00.60 *
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

58
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
59
57 STEERING DEFENDER 90

57.10 POWER STEERING RACK/BOX ASSEMBLY

57.10.01 Power steering rack/box - replace . ................................................ 01.80 5F4 57.10.07 Power
steering rack/box - overhaul . .............................................. 03.20 5F4 57.10.13 Power steering rack/box -
adjust . .................................................. 00.40 *

57.15 POWER STEERING OIL SYSTEM

57.15.01 Power steering system - test . ........................................................ 01.30 * 57.15.02 Power
steering system - bleed . .................................................... 00.30 * 57.15.08 Reservoir - power steering oil -
replace. . ...................................... 00.40 5G5 57.15.20 Hose - feed - steering pump - replace .
.......................................... 00.50 5G4 57.15.21 Pipe/hose - feed - steering rack/box - replace .
.............................. 00.40 5G4 57.15.22 Pipe/hose - return - steering rack/box - replace . ............................
00.50 5G4

57.20 POWER STEERING PUMP

57.20.14 Pump - steering - replace . ............................................................ 00.90 5G1 57.20.15 Pulley -
replace . ............................................................................ 00.50 2H4 57.20.20 Pump - steering - overhaul .
.......................................................... 01.80 5G1

57.35 STEERING RACK/BOX ADJUSTMENT

57.35.01 Steering box - adjust . .................................................................... 00.40 5F1 57.35.05 Steering
rack/box - centralise. . ...................................................... 00.40
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

60
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE
A - WRONGLY ADJUSTED
61
57 STEERING DEFENDER 90

57.40 STEERING COLUMN

57.40.01 Column assembly - inner & outer - replace . .................................. 02.50 5D4 57.40.10 Column -
assembly - overhaul . ...................................................... 02.80 * 57.40.16 Shaft - column - lower - replace .
.................................................... 00.30 5D4 57.40.26 Universal joint - column - upper - replace .
.................................... 00.30 5D6 57.40.27 Universal joint - column - lower - replace .
...................................... 00.30 5D0 57.40.29 Surround - column - complete - replace .
...................................... 00.40 8E7 57.40.31 Column lock & ignition/starter switch assembly - replace .
............ 00.70 5D5

57.50 STEERING IDLER/RELAY UNIT

57.50.14 Drop arm - replace . ........................................................................ 00.60 5E7

57.55 STEERING RODS

57.55.07 Ball joint - track rod - each - replace . ............................................ 00.50 5E3 57.55.08 Ball joints -
track rod - set - replace . .............................................. 00.60 5E3 57.55.09 Track rod - replace .
........................................................................ 01.00 5E3 57.55.15 Ball joint - side rod/drag link - each -
replace . ................................ 00.80 5E5 57.55.17 Side rod/drag link - replace .
.......................................................... 00.80 5E5 57.55.21 Damper - steering box - replace .
.................................................. 00.40 5E1

57.60 STEERING WHEEL

57.60.01 Steering wheel - replace . .............................................................. 00.30 5D1 57.60.03 Pad -
steering wheel - replace. . .................................................... 00.10 8E8

57.65 WHEEL ALIGNMENT

57.65.01 Front wheel alignment - check & adjust . ........................................ 00.50 5E6 57.65.03 Lock stops
- check and adjust . ...................................................... 00.40 5E2
 B - POROUS/ADRIFT SHORT CIRCUIT/THREAD DAMAGE U
C - BAD FIT - INACCURATE/SLIPPING
D - BROKEN V - BULB/LIGHT UNIT FAILURE W -
E - CRACKED/SPLIT/CUT VIBRATION/OUT OF BALANCE X -
F - SEIZED/STIFF BRAKE PULL/SURFACE DAMAGE Z
G - LOOSE/SEAK SYNCHROMESH - INOPERATIVE
H - CORRODED/PLATING
FAILURE

62
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
A - WRONGLY ADJUSTED
63
60 FRONT SUSPENSION DEFENDER 90 (Operations do not include wheel
alignment)

60.10 ANTI SWAY BARS/STABILISERS

60.10.01 Anti sway bar - replace . ................................................................ 00.60 5J5 60.10.03 Ball joint
links - anti sway bar - both sides - replace . .................... 00.50 5J7 60.10.04 Ball joint link - anti sway bar -
each - replace . ................................ 00.40 5J7 60.10.05 Rubber mountings - anti sway bar - set - replace .
........................ 00.40 5J6 60.10.07 Bush(s) - Panhard rod - replace . .................................................. 00.60
5J4 60.10.10 Stabiliser/panhard/tie rod - replace . .............................................. 00.60 5J3 60.10.16 Radius
rod - replace. . .................................................................... 00.80 5H1 60.10.17 Radius rods - both sides -
replace . ................................................ 01.00 5H1 60.10.19 Bush(s) - radius rod - both sides - replace .
.................................... 01.00 5H1 60.10.20 Bush(s) - radius rod - one side - replace .
...................................... 00.80 5H1
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

64
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z
- INOPERATIVE

A - WRONGLY ADJUSTED
65
60 FRONT SUSPENSION DEFENDER 90 (Operations do not include wheel
alignment)

60.15 BALL JOINTS & KNUCKLES

60.15.20 Housing - swivel pin - LH - replace . .............................................. 01.90 5H6 60.15.21 Housing -
swivel pin - RH - replace . .............................................. 02.00 5H6 60.15.22 Housings - swivel pins - both
sides - replace . ................................ 03.70 5H6 60.15.33 Housing - swivel pin bearing - LH - replace .
.................................. 01.90 5H6 60.15.34 Housing - swivel pin bearing - RH - replace .
.................................. 02.00 5H6 60.15.35 Housing - swivel pin bearing - both sides - replace .
...................... 03.70 5H6 60.15.39 Oil seals - swivel pin housing - outer - both sides - replace . ..........
03.70 5H0 60.15.40 Oil seal - swivel pin housing - outer - LH - replace . ...................... 01.90 5H0 60.15.41
Oil seal - swivel pin housing - outer - RH - replace . ...................... 02.00 5H0 60.15.42 Constant velocity
joint - swivel pin housing - both sides - replace . 02.30 5H8 60.15.43 Constant velocity joint - swivel pin
housing - one side - replace . .. 01.30 5H8
60.15.46 Constant velocity joint - swivel pin housing - RH - remove & .
reinstall .............. 01.30 5H8
..........................................................................
60.15.48 Bearings - swivel pin - both sides - replace . .................................. 03.70 5H8 60.15.49 Bearings -
swivel pin - LH - replace . .............................................. 01.90 5H8 60.15.50 Bearings - swivel pin - RH -
replace . ............................................ 01.90 5H8 60.15.54 Bearings - swivel pin - both sides - adjust .
.................................... 03.70 5H8 60.15.55 Bearings - swivel pin - LH - adjust .
................................................ 01.90 5H8 60.15.56 Bearings - swivel pin - RH - adjust .
................................................ 02.00 5H8 60.15.57 Gaskets - swivel pin bearing housing - both sides -
 replace . ........ 03.70 5H0 60.15.58 Gasket - swivel pin bearing housing - LH - replace. . .................... 01.90
5H0 60.15.59 Gasket - swivel pin bearing housing - RH - replace. . .................... 02.00 5H0 60.15.63 Oil
seals - hub & swivel assembly - replace . ................................ 02.00 5H0 60.15.64 Oil seals - hub and
swivel assembly - RH - replace. . .................... 02.00 5H0 60.15.65 Oil seals - hub & swivel assembly - both
sides - replace . .............. 03.70 5H0
B - POROUS/ADRIFT V - BULB/LIGHT UNIT FAILURE W -
C - BAD FIT VIBRATION/OUT OF BALANCE X -
D - BROKEN BRAKE PULL/SURFACE DAMAGE Z
E - CRACKED/SPLIT/CUT - INOPERATIVE
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

66
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
A - WRONGLY ADJUSTED
67
60 FRONT SUSPENSION DEFENDER 90 (Operations do not include wheel
alignment)

60.20 ROAD SPRINGS

60.20.02 Spring assemblies - both sides - replace. . .................................... 01.10 5N1 60.20.03 Spring
seats - lower - both sides - replace . .................................... 01.30 5N2 60.20.04 Spring seats - lower - one
side - replace . ...................................... 00.70 5N2 60.20.11 Road spring - each - replace .
........................................................ 00.60 5N1

60.25 HUBS, DRIVE FLANGES & WHEELS

60.25.01 Hub - each - replace. . .................................................................... 01.40 5V1 60.25.03 Hubs -
both sides - replace . .......................................................... 02.50 5V1 60.25.12 Bearings - hubs - both sides
- check & adjust end float . ................ 00.80 5V4 60.25.13 Bearings - hub - one side - check & adjust end
float . .................... 00.50 5V4 60.25.14 Bearings - hub - one side - replace . ..............................................
01.40 5V4 60.25.15 Oil seals - hub - one side - replace . .............................................. 00.90 5V3 60.25.16
Bearings - hubs - both sides - replace . .......................................... 02.50 5V4 60.25.17 Oil seals - hubs -
both sides - replace . .......................................... 01.60 5V3 60.25.21 Stub axles - both sides - replace .
.................................................. 02.50 5H7 60.25.22 Stub axle - one side - replace. .
...................................................... 01.40 5H7 60.25.37 Oil seal - front hub stub axle - one side - replace .
........................ 01.30 5V3 60.25.38 Oil seals - front hub stub axle - both sides - replace . ....................
02.40 5V3

60.30 SUSPENSION DAMPERS & STOP RUBBERS

60.30.01 Dampers - both sides - replace. . .................................................... 01.10 5R1 60.30.02 Damper -
one side - replace . ........................................................ 00.70 5R1 60.30.03 Dampers - front & rear -
remove & reinstall . .................................. 02.20 5R1 60.30.06 Mounting turret - front - both sides - remove
& reinstall . ................ 01.10 5R4 60.30.08 Mounting rubber - damper - one side - replace .
............................ 00.40 5R4 60.30.09 Bump stops - both sides - replace . ................................................
00.40 5N7 60.30.10 Bump stop(s) - one side - replace . ................................................ 00.40 5N7
 B - POROUS/ADRIFT S - OPEN CIRCUIT/BLOCKED T -
C - BAD FIT SHORT CIRCUIT/THREAD DAMAGE U
D - BROKEN - INACCURATE/SLIPPING
E - CRACKED/SPLIT/CUT V - BULB/LIGHT UNIT FAILURE W -
F - SEIZED/STIFF VIBRATION/OUT OF BALANCE X -
G - LOOSE/SEAK SYNCHROMESH BRAKE PULL/SURFACE DAMAGE Z
H - CORRODED/PLATING - INOPERATIVE
FAILURE

68
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
A - WRONGLY ADJUSTED
69
64 REAR SUSPENSION DEFENDER 90 (Operations do not include wheel alignment)

64.15 HUBS
64.15.01 Hub - each - replace. . .................................................................... 01.30 5W1 64.15.03 Hubs -
both sides - replace . .......................................................... 02.30 5W1 64.15.12 Bearings - hubs - both
sides - check & adjust end float . ................ 00.80 5W4 64.15.13 Bearings - hub - one side - check & adjust
end float . .................... 00.50 5W4 64.15.14 Bearing(s) - hub - one side - replace .
............................................ 01.20 5W4 64.15.15 Oil seal(s) - hub - one side - replace .
............................................ 00.70 5W3 64.15.16 Oil seals - hubs - both sides - replace .
.......................................... 01.20 5W3 64.15.17 Bearings - hubs - both sides - replace .
.......................................... 02.20 5W4 64.15.19 Stub axles - rear - both sides - replace. .
........................................ 01.40 5W2 64.15.20 Stub axle - each - replace .
............................................................ 00.80 5W2 64.15.22 Oil seal - rear stub axle - LH/each - replace .
................................ 00.80 5W3 64.15.23 Oil seals - rear stub axles - both sides - replace. .
.......................... 01.50 5W3

64.20 ROAD SPRINGS

64.20.01 Road spring - each - replace . ........................................................ 00.60 5P1 64.20.02 Spring
assemblies - both sides - replace. . .................................... 01.10 5P1

64.30 SUSPENSION DAMPERS & RUBBER STOPS

64.30.01 Dampers - both sides - replace. . .................................................... 01.00 5R5 64.30.02 Dampers -
one side - replace . ...................................................... 00.60 5R5 64.30.06 Brackets - damper top
mountings - both sides - replace . .............. 01.10 5R4 64.30.07 Bracket - damper top mounting - each -
replace . .......................... 00.60 5R4 64.30.13 Bump stop/arch spring - both sides - replace .
.............................. 00.50 5P7 64.30.15 Bump stop - one side - replace. . ....................................................
00.30 5P7 64.30.19 Ball joints - axle bracket - replace . ................................................ 00.80 5L7

64.35 SUSPENSION LINKS & ARMS

64.35.02 Suspension link - lower - replace . .................................................. 00.30 5L1 64.35.04 Bushing -
suspension link - upper - one side - replace . ................ 00.40 5L2 64.35.05 Bushing - suspension link -
lower - one side - replace . .................. 00.30 5L1 64.35.06 Bushing - suspension link - upper - both sides -
replace . .............. 00.40 5L2 64.35.07 Bushing - suspension link - lower - both sides - replace . ..............
00.40 5L1 64.35.08 Anti sway bar - replace . ................................................................ 00.30 5M7
64.35.08/01 Anti sway bar - replace . ................................................................ 00.20 64.35.11 Suspension
links - upper - both sides - replace . ............................ 00.70 5L2 64.35.12 Suspension links - lower - both
sides - replace . ............................ 00.40 5L1 64.35.18 Rubber bushing - anti sway bar - set - replace .
............................ 00.30 5J6 64.35.24 Link - anti sway bar - replace. . ......................................................
00.30 5J8 64.35.27 Links - anti sway bar - rear - both sides - replace . ........................ 00.40 5J8 64.35.42
Flexible mountings - lower suspension link - both sides - replace . 00.40 5L1 64.35.43 Flexible mountings -
 lower suspension link - one side - replace . .. 00.30 5L1 64.35.44 Suspension link - upper - one side -
replace . ................................ 00.40 5L2
H - CORRODED/PLATING FADED/STAINED/DISCOLOURED R -
FAILURE FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
A - WRONGLY ADJUSTED 70 - INACCURATE/SLIPPING
B - POROUS/ADRIFT J - WORN/STRETCHED
V - BULB/LIGHT UNIT FAILURE W -
C - BAD FIT K - NOISY/CHAFED
VIBRATION/OUT OF BALANCE X -
D - BROKEN L - JUDDER/POOR CONNECTION M
BRAKE PULL/SURFACE DAMAGE Z -
E - CRACKED/SPLIT/CUT - BODY/COOLANT LEAKS/BURNT N
INOPERATIVE
F - SEIZED/STIFF - LEAKS - NOT COOLANT LOSS P -
G - LOOSE/SEAK SYNCHROMESH DIFFICULT ENGAGEMENT Q -

71
70 BRAKES DEFENDER 90 (Operations include bleeding brakes where necessary)

70.10 ROTORS & DRUMS

(Includes check new rotor(s) for runout)
70.10.03 Drum - rear - each - replace . ........................................................ 00.50 6F1 70.10.05 Drums -
rear - set - replace . .......................................................... 00.70 6F1 70.10.09 Rotors - vehicle set - replace.
. ...................................................... 04.70 * 70.10.10 Rotor - front - each - replace. .
........................................................ 01.30 6C1 70.10.12 Rotors - front - set - replace. .
........................................................ 02.50 6C1 70.10.13 Rotors - rear - set - replace .
.......................................................... 02.30 6D1 70.10.17 Rotor shields - vehicle set - replace .
.............................................. 01.40 6C7 70.10.18 Rotor shield(s) - front - each - replace. .
........................................ 00.50 6C7 70.10.19 Rotor shield(s) - rear - each - replace .
.......................................... 00.40 6D7 70.10.21 Rotor shields - front - axle set - replace .
........................................ 00.70 6C7 70.10.24 Back plates - rear - both sides - replace .
...................................... 02.80 6F3 70.10.28 Back plate - rear - each - replace .
................................................ 02.00 6F3 70.10.29 Rotor shields - rear - axle set - replace .
........................................ 00.60 6D7

70.15 HOSES & CONNECTORS Includes bleeding system

70.15.01 Hoses - complete set - replace. . .................................................... 01.60 6G4 70.15.02 Hose -
front - primary - LH/each - replace . .................................... 00.80 6G4 70.15.04 Hose - center/intermediate
- replace . ............................................ 00.70 6G4 70.15.10 Hoses - front - set - replace .
.......................................................... 01.10 6G4

70.25 HYDRAULIC SYSTEM

70.25.02 Brakes - complete system - bleed . ................................................ 00.50 6C0 70.25.03 Brakes -
adjust . .............................................................................. 00.30 * 70.25.16 Seals - brake system - set -
replace . ............................................ 03.70 * 70.25.18 Seals & hoses - brake system - set - replace .
.............................. 04.20 * 70.25.21 Valve - pressure reducing - replace . ..............................................
00.90 6G6
 B - POROUS/ADRIFT S - OPEN CIRCUIT/BLOCKED T -
C - BAD FIT SHORT CIRCUIT/THREAD DAMAGE U
D - BROKEN - INACCURATE/SLIPPING
E - CRACKED/SPLIT/CUT V - BULB/LIGHT UNIT FAILURE W -
F - SEIZED/STIFF VIBRATION/OUT OF BALANCE X -
G - LOOSE/SEAK SYNCHROMESH BRAKE PULL/SURFACE DAMAGE Z -
H - CORRODED/PLATING INOPERATIVE
FAILURE

72
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
A - WRONGLY ADJUSTED
73
70 BRAKES DEFENDER 90 (Operations include bleeding brakes where necessary)

70.30 MASTER CYLINDER

70.30.08 Cylinder - master - tandem - replace . ............................................ 00.90 6G1 70.30.09 Cylinder -
master - tandem - overhaul . .......................................... 01.10 6G1

70.35 MECHANICAL LINKAGE

70.35.01 Pedal - brake - replace . ................................................................ 01.50 6J1 70.35.03 Pedal box -
replace . ...................................................................... 01.40 * 70.35.10 Cable(s)/rod(s) - parking brake -
adjust . ........................................ 00.30 6A3 70.35.25 Cable - parking brake - each - replace .
........................................ 00.80 6A3 70.35.42 Switch - stop light - replace .
.......................................................... 00.40 7N1 70.35.60 Pad cover - brake pedal - replace .
................................................ 00.10 6J5

70.40 PADS/SHOES
70.40.01 Pads/shoes - vehicle set - replace . ................................................ 01.40 * 70.40.02 Pads/shoes -
front - set - replace . .................................................. 00.80 6C2 70.40.03 Pads/shoes - rear - set - replace .
.................................................. 00.80 6D2

70.45 TRANSMISSION BRAKE

70.45.01 Hand lever - transmission brake - replace . .................................... 00.40 6A1 70.45.09
Transmission brake - adjust . .......................................................... 00.30 6B1 70.45.15 Back plate -
transmission brake - replace . .................................... 00.80 6F3 70.45.17 Drum - transmission brake -
replace . ............................................ 00.50 6F1 70.45.18 Shoes - transmission brake - replace .
.......................................... 00.70 6B2

70.50 VACUUM SYSTEM

70.50.01 Servo assembly - replace . ............................................................ 01.10 6H1 70.50.14 Hose -
manifold to servo - replace . ................................................ 00.20 6H3 70.50.15 Valve - non return - replace
. .......................................................... 00.20 6H4
 B - POROUS/ADRIFT S - OPEN CIRCUIT/BLOCKED T -
C - BAD FIT SHORT CIRCUIT/THREAD DAMAGE U
D - BROKEN - INACCURATE/SLIPPING
E - CRACKED/SPLIT/CUT V - BULB/LIGHT UNIT FAILURE W -
F - SEIZED/STIFF VIBRATION/OUT OF BALANCE X -
G - LOOSE/SEAK SYNCHROMESH BRAKE PULL/SURFACE DAMAGE Z -
H - CORRODED/PLATING INOPERATIVE
FAILURE

74
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
A - WRONGLY ADJUSTED
75
70 BRAKES DEFENDER 90 (Operations include bleeding brakes where necessary)

70.55 WHEEL/BRAKE CALIPERS

70.55.01 Calipers - vehicle set - replace . .................................................... 01.80 * 70.55.02 Caliper - front
- each - replace . ...................................................... 00.60 6C3 70.55.03 Caliper - rear - each - replace .
...................................................... 00.60 6D3 70.55.05 Calipers - front - set - replace .
...................................................... 01.00 6C3 70.55.06 Calipers - rear - set - replace .
........................................................ 01.00 6D3 70.55.12 Calipers - vehicle set - overhaul .
.................................................. 03.10 * 70.55.13 Caliper - front - each - overhaul .
.................................................... 01.00 6C3 70.55.14 Caliper - rear - each - overhaul .
.................................................... 00.90 6D3 70.55.16 Calipers - front - set - overhaul .
.................................................... 01.80 6C3 70.55.17 Calipers - rear - set - overhaul .
...................................................... 01.50 6D3

70.60 WHEEL CYLINDERS

70.60.17 Wheel cylinders - rear - both sides - replace . ................................ 02.00 6F4 70.60.19 Wheel
cylinder - rear - each - replace . .......................................... 01.30 6F4 70.60.25 Wheel cylinders - rear -
both sides - overhaul . .............................. 02.40 6F4 70.60.26 Wheel cylinder - rear - each - overhaul .
........................................ 01.60 6F4
 B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

76
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z -
INOPERATIVE

A - WRONGLY ADJUSTED
77
76 BODY DEFENDER 90

76.10 BODY - GENERAL

76.10.13 Panel - roof - replace . .................................................................... 05.70 9A2 76.10.17 Sun visors
- pair - replace . ............................................................ 00.20 8S4 76.10.24 Fender - front - LH/each -
remove for access & reinstall . .............. 02.80 9A3 76.10.47 Sun visor - each - replace .
............................................................ 00.20 8S4 76.10.51 Mirror - interior - replace .
.............................................................. 00.20 8S3 76.10.52 Mirror - exterior - each - replace .
.................................................. 00.60 9P1 76.10.55 Panel - fender outer - front - RH - replace .
.................................... 02.10 9T5 76.10.56 Panel - fender outer - front - LH - replace .
.................................... 02.50 9T5 76.10.63 Panel - fender inner - front - LH - replace .
.................................... 02.30
76.10.64 Panel - fender inner - front - RH - replace . .................................... 02.10 76.10.68 Panel - front
floor - passenger side - replace . ................................ 00.70 9B2 76.10.69 Panel - front floor - drivers side -
replace . ...................................... 00.70 76.10.70 Panel - cover - transmission - replace .
.......................................... 00.80 8E3 76.10.71 Panel - cover - transmission bell housing - replace .
...................... 00.50 8E3 76.10.92 Cross member - chassis - remove and reinstall . ............................
01.50 5A3

76.11 BODY - GENERAL (cont.)

76.11.15 Acoustic cover - transmission - LH side - replace . ........................ 01.00
76.11.16 Turret cover - damper - front - both sides - replace . ...................... 00.40
76.11.28 Panel - mounting - inner door - front - remove for access & .
reinstall ............................. 00.70
...........................................................
76.11.39 Roll-over bar - exterior - replace . .................................................. 00.60 76.11.40 Roll-over bar -
interior - replace . .................................................... 02.30 76.11.41 Tow bar - replace .
 .......................................................................... 00.50 5B3 76.11.42 Roll-over bar - interior - rear - replace .
.......................................... 02.10

A - WRONGLY ADJUSTED
B - POROUS/ADRIFT
C - BAD FIT
D - BROKEN
E - CRACKED/SPLIT/CUT
F - SEIZED/STIFF
G - LOOSE/SEAK SYNCHROMESH
H - CORRODED/PLATING
FAILURE

78
J - WORN/STRETCHED
K - NOISY/CHAFED
L - JUDDER/POOR CONNECTION M
- BODY/COOLANT LEAKS/BURNT N
- LEAKS - NOT COOLANT LOSS P -
DIFFICULT ENGAGEMENT Q -
FADED/STAINED/DISCOLOURED R -
FACTORY DAMAGE
S - OPEN CIRCUIT/BLOCKED T -
SHORT CIRCUIT/THREAD DAMAGE U
- INACCURATE/SLIPPING
V - BULB/LIGHT UNIT FAILURE W -
VIBRATION/OUT OF BALANCE X -
BRAKE PULL/SURFACE DAMAGE Z -
INOPERATIVE