INSTALLING YOUR NEW SX ROVERDRIVE

To make these instructions clear some photographs have been taken using a transmission that is not mounted in a Series Land Rover. To do this installation you will need a good set of mechanic’s tools including a ½ inch torque wrench, a 2 inch (25mm) hole saw, and an electric drill. You will also need 3 litres of SAE 75-90 gear oil. (Synthetic is preferred.) and a small amount of grease. 

1. Before you start the installation examine the transfer case. If there are any signs of leaks install new seals and gaskets before fitting the Roverdrive. (Our Seal kit ODSX003). This is also a good time to check the pre-load on the roller bearings on the output shaft. This is a simple procedure outlined in the vehicle workshop manual. To start the installation clean the areas where you will be working. Now remove the top cover and end cover from the transfer case. Keep the studs in the top of the transfer case but remove the studs from the rear of the case using a Vise Grip.

2. Using a small flat screwdriver bend up the locking tab retaining the castle nut on the shaft inside. Using a hammer and a dull chisel or metal drift tap the nut loose. (Right hand thread !) Now withdraw the nut, washers and gear from the transfer case through the hole in the back. Do not drop any components into the case! Store the studs, nuts, covers and gear in case you decide to transfer the Roverdrive to another vehicle. Scrape off all old gaskets and clean surfaces. Brake cleaner is excellent for this task.

3. Insert the coupling over the mainshaft in the transfer case - roller bearing, end first. Using the socket provided, screw on the hexagonal nut over the end of the shaft and tighten it to a torque of 100 lb.ft. To stop the shaft turning, block your hand crank in the front of the engine, and engage first gear. To lock the nut in place use the hexagonal key provided and tighten the two socket screws that are placed on opposite sides of the coupling. These screws do not require a lot of torque. If you make them too tight you may damage the screws or force the coupling off centre.

4. Unscrew the oil level plug from the back of the transfer case and store this with other parts. Unscrew the elbow and reducing bush from the nut on the dipstick assembly. Now screw the elbow and bush into the oil level port using a thread sealant. Stop tightening when the elbow is secure and pointing upwards. Next attach the dipstick tube and tighten the nut firmly. The speedometer cable is not shown in the picture. It should pass between the dipstick and the back of the transfer case.

5. Loosen the two bolts securing the halves of the Roverdrive casing and discard the nuts. Separate the front and back casings. Grease the paper gasket and place over the front casing nose. Do not use gasket cement. Using one bolt to align the gasket, slide the casing into the transfer case with the nameplate uppermost. DO NOT FORCE. If the unit will not slide all the way in investigate the cause. You may have to tap the steel disc on the mainshaft forward somewhat to clear the end of the Roverdrive gear.

6. Grease the 'O' ring to hold it in position in the front cover. Fit the main casing with the actuating shaft in the 'Two O’ Clock' position. The casing will require some twisting to enable the gears to engage. Secure the unit using a 9/16 wrench and the six 3/8 U.N.C. bolts provided. The six 'Dowty' washers with rubber inserts must be fitted under the heads of the bolts before securing. Fit the new cover plate on top of the transfer case using the gasket provided and the nuts and spring washers from the old cover. 

If you are installing the aluminium finned bottom cover plate, Part No. 839713, it should be installed at this time.

7. Remove the two 5/16 bolts from the top of the transfer case and fit the L bracket on the right hand side using the two new 5/16 bolts, nuts and washers provided. (On six cylinder installations the L bracket will be too short and must be extended two inches forward by welding in an extension piece). Now drill a small pilot hole through the right hand side of the tunnel cover to align with the threaded hole in the L bracket. (A few trial holes may be needed to get this right). Enlarge the aligned hole with a hole saw to two inches (50mm) dia.

8. Work the gear lever assembly through the new hole in the tunnel cover and secure the hinge bolt. The link turnbuckle is now installed, adjusted and secured with the locknuts provided as shown. Make sure no floor screws interfere with the linkage assembly or this will cause vibration. Fit the 3/8 UNF locknut to secure the link. In some installations you may wish to bend the shift lever to suit your requirements. Fit the rubber boot and trim ring using the three self tapping screws as shown here. 

9. Fill the transfer case using the new filler plug in the rectangular plate on top. Fill until oil shows on the tip of the dipstick. (Do not fill more than 10mm from the tip.) Remove the plug from the overdrive housing and add ½ litre of oil to this housing. A good quality 75-90 weight oil should be used. Check installation for leaks. After the first 1000 miles drain the oil and replace. You may wish to use a synthetic or semi-synthetic oil at this point. Check oil frequently during use.

3396 Marine Drive, West Vancouver, BC CANADA, V7V 1M9
Telephone (604) 913-7910 Fax (604) 921-7290