Land Rover Defender: Transfer Case Front Output Seal

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

205-818

Installer, Seal

308-636

Installer

JLR-308-926

Support Tool, Transfer Case

GENERAL EQUIPMENT

PART(S)

REMOVAL

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Raise and support the vehicle on a suitable 2 post lift.

2. Remove the transfer case.

3. With assistance, secure the transfer case with its transmission mating face down on a flat surface.

4.

• Remove the bolt.
• Remove the Noise, Vibration and Harshness (NVH) damper.

5.

• Remove the 2 bolts.
• Remove the Transmission Control Module (TCM).

6.

• Remove the 2 bolts.
• Remove the sensor.

7.

CAUTION: Make sure the bolt holes are clean and free of swarf.

Remove the 19 transfer case bolts.

8.

CAUTION: Care must be taken when turning the transfer case over. The transfer case halves must not be allowed to separate.

With assistance, release the transfer case and secure with the rear face of the transfer case facing down on a flat surface.

9.

CAUTION: Care must be taken to avoid damage to the mating surfaces.

• Use a soft faced mallet to release the front casing.
• Release the clip.

10. Clean the component mating face.

11.

Use the special tool to support the output shaft flange.

Special Tool(s): JLR-308-926

12.

Remove the circlip.

13.

CAUTION: Do not use excessive force when removing the flange assembly.

Remove the front output shaft and flange assembly.

14.

• Use a suitable tool to remove the seal.
• Discard the seal.

INSTALLATION

1.

• Use the special tool to install a new seal.

  Special Tool(s): 308-636.

  Renew Part: Transfer case front output shaft oil seal Quantity: 1.

2.

Use the special tool to install the drive flange.

Special Tool(s): 205-818

3.

NOTE: Check that the circlip is fully engaged.

Install the circlip.

4.

Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.

5.

CAUTION:

• Make sure that the input shaft spacer is located correctly.
• The input shaft and fluid pump assembly must be supported and held in place by hand, until it is located securely into the clutch assembly.

Install the front half of the transfer case.

6.

CAUTION: Care must be taken when turning the transfer case over. The transfer case halves must not be allowed to separate.

With assistance, release the transfer case and secure with its transmission mating face down on a flat surface.

7.

CAUTION: Only tighten the bolts finger-tight at this stage.

Install the 19 transfer case case bolts.

8.

Tighten the 2 bolts to the specified torque.

Torque: 10Nm

9.

Fully tighten the 19 bolts.

Torque: 35Nm

10.

• Install the Transmission Control Module (TCM).
• Install and tighten the 2 bolts.

  Torque: 35Nm

11.

• Install the sensor.
• Install and tighten the 2 bolts.

  Torque: 5Nm

12.

• Install the Noise, Vibration and Harshness (NVH) damper.
• Install and tighten the bolt.

  Torque: 75Nm

13.

NOTE: This step is only required if previously removed.

• Install the heatshield.
• Install and tighten the 3 bolts.

  Torque: 8Nm

14.

NOTE: This step is only required if previously removed.

• Install the heatshield.
• Install and tighten the 2 bolts.

  Torque: 8Nm

15. With assistance, release the transfer case from the flat surface.

16. Install the transfer case.

17.

• Connect the Jaguar Land Rover approved diagnostic equipment.

  General Equipment: Jaguar Land Rover approved diagnostic equipment

• Start the diagnostic service function "transfer case-transfer case control module replacement".
• Start the service function "transfer case-absolute position sensor replacement".
• Clear any Diagnostic Trouble Codes (DTCs) after calibration and check for correct operation.

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