REMOVAL AND INSTALLATION
SPECIAL TOOL(S)
205-726
Remover/Installer, Wheel Hub Bearing
303-1119
Installer, Camshaft Seal
308-637
Installer
JLR-308-927
Support Tool, Transfer Case
PART(S)
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.
7.
NOTE: If equipped.
8.
9.
10.
11.
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.
Using a soft faced mallet, release the front casing.
14. Clean the component mating faces.
15.
Locate the magnetic filter. The filter may have dropped into the front housing in the previous step.
16.
Remove the transfer case chain assembly.
17.
18.
CAUTION: Note the installed position of the component prior to removal.
Rotate the transfer differential assembly to the position shown in the illustration.
19.
CAUTION: Note the installed position of the component prior to removal.
20.
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.
22.
Install the special tool.
Special Tool(s): JLR-308-927
23.
Remove and discard the circlip.
24.
CAUTION: Do not use excessive force when removing the flange assembly.
Remove the rear output shaft flange.
25.
Special Tool(s): 303-1119
26.
Remove and discard the seal.
INSTALLATION
1.
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.
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.
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.
Make sure the transfer case flange seal cover is install on the flange.
6.
NOTE: Check that the circlip is fully engaged.
Install a new circlip.
Renew Part: Circlip Quantity: 1.
7.
NOTE: Rotate the differential to engage the splines.
Install the transfer differential assembly.
8.
NOTE: Check that the circlip is fully engaged.
Install a new circlip.
Renew Part: Circlip Quantity: 1.
9.
NOTE: Make sure that the component is installed to the noted removal position.
10.
Torque: 15Nm
11.
Install the transfer case chain assembly.
12.
CAUTION: Make sure that the component is clean and free of foreign material.
Install the magnetic filter.
13.
Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.
14.
CAUTION:
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.
Install and tighten the 19 bolts finger tight.
17.
Tighten the 2 bolts to the correct torque.
Torque: 10Nm
18.
Fully tighten the 19 bolts.
Torque: 35Nm
19.
Torque: 35Nm
20.
Torque: 75Nm
21.
Torque: 5Nm
22.
NOTE: This step is only required if previously removed.
Torque: 8Nm
23.
NOTE: This step is only required if previously removed.
Torque: 8Nm
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.