Land Rover Defender: Transfer Case Rear Output Seal

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

308-637

Installer

JLR-308-927

Support Tool, Transfer Case

PART(S)

REMOVAL

NOTE:

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

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.

NOTE: If equipped.

• Remove the 3 bolts.
• Remove the heatshield.

5.

NOTE: If equipped.

• Remove the 2 bolts.
• Remove the heatshield.

6.

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

7.

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

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

8.

• Remove the 2 bolts.
• Remove the sensor.

9.

Remove the 19 transfer case bolts.

10.

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.

11.

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

Use a soft faced mallet, release the front casing.

12. Clean the component mating faces.

13.

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

14.

Remove the transfer case chain assembly.

15.

• Remove the 2 bolts.
• Remove the bracket.

16.

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

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

17.

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

• Remove the washer.
• Remove the components.

18.

Remove and discard the circlip.

19.

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

Remove the transfer differential assembly.

20.

Install the special tool.

Install the Special Tool(s): JLR-308-927

21.

Remove and discard the circlip.

22.

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

Remove the rear output shaft flange.

23.

Remove and discard the seal.

INSTALLATION

1.

• Use the special tool to install a new seal.

  Install the Special Tool(s): 308-637

2.

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

3.

NOTE: Check that the circlip is fully engaged.

Install a new circlip.

Renew Part: Circlip Quantity: 1.

4.

NOTE: Rotate the differential to engage the splines.

Install the transfer differential assembly.

5.

NOTE: Check that the circlip is fully engaged.

Install a new circlip.

Renew Part: Circlip Quantity: 1.

6.

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

• Install the component.
• Install the washer.

7.

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

  Torque: 15Nm

8.

Install the transfer case chain assembly.

9.

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

Install the magnetic filter.

10.

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

11.

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.

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 its transmission mating face down on a flat surface.

13.

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

Install and tighten the 19 bolts finger tight.

14.

Tighten the 2 bolts to the correct torque.

Torque: 10Nm

15.

Fully tighten the 19 bolts.

Torque: 35Nm

16.

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

  Torque: 35Nm

17.

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

  Torque: 75Nm

18.

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

  Torque: 5Nm

19.

NOTE: This step is only required if previously removed.

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

  Torque: 8Nm

20.

NOTE: This step is only required if previously removed.

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

  Torque: 8Nm

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

22. Install the transfer case.

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