Land Rover Defender: Transfer Case - Installation

INSTALLATION

SPECIAL TOOL(S)

303-1069

Adapter, Wrench

PART(S)

NOTES:

• 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.

• Steps 1 to 3 are only required if the components were previously removed.

1.

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

  Torque: 5Nm

2.

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

  Torque: 72Nm

3.

NOTE: This step is only required if the existing transfer case is to be used.

Install a new O-ring seal.

Renew Part: Transfer case connecting sleeve O-ring seal kit Quantity: 1.

4.

WARNING: This step requires the aid of another technician.

• Install the transfer case.
• Use the special tool to install and tighten the 8 bolts.

  Special Tool(s): 303-1069.

  Torque: 40Nm

5.

CAUTION: To prevent water ingress and subsequent transmission damage, make sure that the breather is fully installed into the transmission casing. The white line around the circumference of the pipe should not be visible when correctly installed.

• Install the breather pipe.
• Install the clip.

6.

• Install and tighten the 2 bolts.

  Torque: 24Nm

• Connect the 2 electrical connectors.
• Install the wiring harness clip.

7.

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

  Torque: 8Nm

8.

• Install the exhaust NVH damper.
• Install and tighten the 4 bolts.

  Torque: 60Nm

9.

• Install the transfer case ground cable.
• Install and tighten the bolt.

  Torque: 24Nm

10. Install the rear driveshaft.

11. Install the transmission support crossmember.

12. Fill the transfer case.

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