Land Rover Defender manuals

Land Rover Defender: Transfer Case Front Output Shaft Bearing

Land Rover Defender 2020-2024 Service Manual / Powertrain / Transfer Case / Transfer Case Front Output Shaft Bearing

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

Transfer Case Front Output Shaft Bearing

205-726

Remover/Installer, Wheel Hub Bearing

Transfer Case Front Output Shaft Bearing

303-1119

Installer, Camshaft Seal

Transfer Case Front Output Shaft Bearing

308-637

Installer

Transfer Case Front Output Shaft Bearing

JLR-308-927

Support Tool, Transfer Case

PART(S)

Transfer Case Front Output Shaft Bearing

REMOVAL

NOTE:

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

2. Disconnect the startup battery ground cable.

3. Drain the transfer case.

4. Remove the transfer case.

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

6.

NOTE: If equipped.

Transfer Case Front Output Shaft Bearing

7.

NOTE: If equipped.

Transfer Case Front Output Shaft Bearing

8.

Transfer Case Front Output Shaft Bearing

9.

Transfer Case Front Output Shaft Bearing

10.

Transfer Case Front Output Shaft Bearing

11.

Transfer Case Front Output Shaft Bearing

Remove the 19 transfer case bolts.

12.

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.

13.

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

Transfer Case Front Output Shaft Bearing

Using a soft faced mallet, release the front casing.

14. Clean the component mating faces.

15.

Transfer Case Front Output Shaft Bearing

Locate the magnetic filter. The filter may have dropped into the front housing in the previous step.

16.

Transfer Case Front Output Shaft Bearing

Remove the transfer case chain assembly.

17.

Transfer Case Front Output Shaft Bearing

18.

CAUTION: Note the installed position of the component prior to removal.

Transfer Case Front Output Shaft Bearing

Rotate the transfer differential assembly to the position shown in the illustration.

19.

CAUTION: Note the installed position of the component prior to removal.

Transfer Case Front Output Shaft Bearing

20.

Transfer Case Front Output Shaft Bearing

Remove and discard the circlip.

21.

CAUTION: Note the installed position of the component prior to removal.

NOTE: Remove both components at the same time.

Transfer Case Front Output Shaft Bearing

22.

Transfer Case Front Output Shaft Bearing

Install the special tool.

Special Tool(s): JLR-308-927

23.

Transfer Case Front Output Shaft Bearing

Remove and discard the circlip.

24.

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

Transfer Case Front Output Shaft Bearing

Remove the rear output shaft flange.

25.

Transfer Case Front Output Shaft Bearing

26.

Transfer Case Front Output Shaft Bearing

Remove and discard the seal.

INSTALLATION

1.

Transfer Case Front Output Shaft Bearing

Position the special tool as shown, to support the transfer case during the next step.

Special Tool(s): JLR-308-927

2.

CAUTION: The chamfer on the bearing inner track must face the seal.

Transfer Case Front Output Shaft Bearing

Use the special tool to install the new bearing.

Special Tool(s): 205-726

3. Remove the special tool.

Special Tool(s): JLR-308-927

4.

Transfer Case Front Output Shaft Bearing

Use the special tool to install a new seal.

Special Tool(s): 308-637

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

5.

Transfer Case Front Output Shaft Bearing

Make sure the transfer case flange seal cover is install on the flange.

6.

NOTE: Check that the circlip is fully engaged.

Transfer Case Front Output Shaft Bearing

Install a new circlip.

Renew Part: Circlip Quantity: 1.

7.

NOTE: Rotate the differential to engage the splines.

Transfer Case Front Output Shaft Bearing

Install the transfer differential assembly.

8.

NOTE: Check that the circlip is fully engaged.

Transfer Case Front Output Shaft Bearing

Install a new circlip.

Renew Part: Circlip Quantity: 1.

9.

NOTE: Make sure that the component is installed to the noted removal position.

Transfer Case Front Output Shaft Bearing

10.

Transfer Case Front Output Shaft Bearing

11.

Transfer Case Front Output Shaft Bearing

Install the transfer case chain assembly.

12.

CAUTION: Make sure that the component is clean and free of foreign material.

Transfer Case Front Output Shaft Bearing

Install the magnetic filter.

13.

Transfer Case Front Output Shaft Bearing

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

14.

CAUTION:

Transfer Case Front Output Shaft Bearing

Install the front half of the transfer case.

15.

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.

16.

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

Transfer Case Front Output Shaft Bearing

Install and tighten the 19 bolts finger tight.

17.

Transfer Case Front Output Shaft Bearing

Tighten the 2 bolts to the correct torque.

Torque: 10Nm

18.

Transfer Case Front Output Shaft Bearing

Fully tighten the 19 bolts.

Torque: 35Nm

19.

Transfer Case Front Output Shaft Bearing

20.

Transfer Case Front Output Shaft Bearing

21.

Transfer Case Front Output Shaft Bearing

22.

NOTE: This step is only required if previously removed.

Transfer Case Front Output Shaft Bearing

23.

NOTE: This step is only required if previously removed.

Transfer Case Front Output Shaft Bearing

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

25. Install the transfer case.

26. Fill the transfer case.

27. Connect the startup battery ground cable.

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