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Home/Land Rover/Range Rover/Land Rover Range Rover III facelift 2 (2009-2012)/Repair manual/Automatic Trans/Transfer Case: Removal & Installation
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Transfer Case: Removal & Installation Land Rover Range Rover III facelift 2

Automatic Trans 38 illustrations ~1269 words

REMOVAL

Note. Some variation in the illustrations may occur, but the essential information is always correct.

Scheme 30

Scheme 30: REMOVAL
Scheme 30: REMOVAL
  1. Raise and support the vehicle.
  2. Remove the transfer case. Refer to «Transfer Case - 5.0L NA V8 - AJ133/5.0L SC V8 - AJ133»(ref-514923) or See «Transfer Case - 5.0L NA V8 - AJ133/5.0L SC V8 - AJ133»(ref-514869-S10896706512012112600000) .
  3. Carefully remove and discard the oil seal. Use the special tools.

Scheme 31

Scheme 31: INSTALLATION
Scheme 31: INSTALLATION
  1. Install a new seal. Clean the seal register. Use the special tool.
  2. Install the transfer case. See «Transfer Case - 5.0L NA V8 - AJ133/5.0L SC V8 - AJ133»(ref-514869-S10896706512012112600000) . .

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Installer 307-486(LRT-41-019) Installer 308-636 Installer 205-818

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Scheme 32: TRANSFER CASE FRONT OUTPUT SHAFT SEAL (5.0L)
Scheme 32: TRANSFER CASE FRONT OUTPUT SHAFT SEAL (5.0L)

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Scheme 33
WARNINGSome variation in the illustrations may occur, but the essential information is always correct.

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  1. Disconnect the battery ground cable. Refer to «Specifications»(ref-514850) article.
  2. Raise and support the vehicle.
  3. Drain the transfer case fluid. See «Transfer Case Draining and Filling»(ref-514869-S38094148362012112600000) .
  4. Remove the transfer case. Refer to «Transfer Case - 5.0L»(ref-514923) or See «Transfer Case - 5.0L»(ref-514869-S10896706512012112600000) .
  5. With assistance, secure the transfer case with its transmission mating face down on a flat surface. Secure with 2 bolts.
  6. Remove the shift motor. Remove the 4 bolts. Remove any debris from the bolt holes.
  7. Remove 17 Torx bolts securing the transfer casings. The two bolts indicated remain fully tightened. Remove any debris from the bolt holes.
  8. With assistance, release the transfer case and secure with the rear face of the transfer case facing down on a flat surface.
  9. Remove the front half of the transfer case. Remove the remaining 2 Torx bolts. Remove any debris from the bolt holes. Use a soft faced mallet.
  10. Remove the 2 special washers.
  11. Remove the input shaft and oil pump assembly. Release the fluid pump pickup line.
  12. Remove the front output flange. Compress the snap ring. Press the flange through the bearing. Remove and discard the snap ring.
  13. Remove the output flange seal.
  14. Remove the output flange bearing.

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Scheme 41: INSTALLATION
Scheme 41: INSTALLATION

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Scheme 46
  1. Remove the sealant from the transfer case mating faces.
  2. Clean the magnetic filter.
  3. Using the special tool, install the output flange bearing. Clean the components mating faces.
  4. Using the special tool, install a new oil seal. Clean the component mating faces. Grease the new seal.
  5. Using the special tool and with assistance, install the drive flange. Clean the component mating faces. Install a new snap ring. Make sure the snap ring is fully engaged and retains the drive flange.
  6. Install the 2 special washers. Clean the components.
  7. Install the input shaft and oil pump assembly. Clean the components. Secure the fluid pickup line.
  8. Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown. Clean the component mating faces. Clean the dowels and dowel holes.
  9. Install the front half of the transfer case. Evenly tighten the 2 Torx bolts shown to 35 Nm (26 lb.ft).
  10. With assistance, release the transfer case and secure with its transmission mating face down on a flat surface.
  11. Tighten the remaining Torx bolts to 35 Nm (26 lb.ft).
  12. Install the shift motor. Clean the components. Tighten the Torx bolts to 25 Nm (18 lb.ft).
  13. With assistance, release the transfer case. Remove the 2 bolts.
  14. Install the transfer case. Refer to «Transfer Case - 5.0L»(ref-514923) or «Transfer Case - 5.0L»(ref-514869-S10896706512012112600000) .
  15. Refill the transfer case with the recommended fluid. See «Transfer Case Draining and Filling»(ref-514869-S38094148362012112600000) .
  16. Connect the battery ground cable. Refer to «Specifications»(ref-514850) article.

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Remover/installer 205-726(LRT-54-015) Seal installer 308-637 Installer 204-525/1

Scheme 47

Scheme 47: TRANSFER CASE REAR OUTPUT SHAFT SEAL (5.0L)
Scheme 47: TRANSFER CASE REAR OUTPUT SHAFT SEAL (5.0L)

Note. Some variation in the illustrations may occur, but the essential information is always correct.

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Scheme 53
  1. Disconnect the battery ground cable. Refer to «Specifications»(ref-514850) article.
  2. Raise and support the vehicle.
  3. Drain the transfer case fluid. See «Transfer Case Draining and Filling»(ref-514869-S38094148362012112600000) .
  4. Remove the transfer case. Refer to «Transfer Case - 5.0L»(ref-514923) or See «Transfer Case - 5.0L»(ref-514869-S10896706512012112600000) .
  5. With assistance, secure the transfer case with its transmission mating face down on a flat surface. Secure with 2 bolts.
  6. Remove the shift motor. Remove the 4 bolts. Remove any debris from the bolt holes.
  7. Remove 17 Torx bolts securing the transfer casings. The two bolts indicated remain fully tightened. Remove any debris from the bolt holes.
  8. Remove the rear half of the transfer case. Remove the remaining 2 Torx bolts. Remove any debris from the bolt holes. Use a soft faced mallet.
  9. Remove the differential module. Remove the spacer.
  10. Remove the clutch, chain and sprocket.
  11. Remove the rear output flange. Compress the snap ring. Press the flange through the bearing. Remove and discard the snap ring.
  12. Remove the output flange seal.
  13. Remove the output flange bearing. Remove the circlip.
  14. Release the front half of the transfer case from the flat surface. Remove the 2 bolts.

Scheme 54

Scheme 54: INSTALLATION
Scheme 54: INSTALLATION

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Scheme 58
  1. Remove the sealant from the transfer case mating faces.
  2. Clean the magnetic filter.
  3. Using the special tool, install the output flange bearing. Clean the components mating faces. Install the circlip.
  4. Using the special tool, install a new oil seal. Clean the component mating faces. Grease the new seal.
  5. Using the special tool and with assistance, install the drive flange. Clean the component mating faces. Install a new snap ring. Make sure the snap ring is fully engaged and retains the drive flange.
  6. Secure the rear half of the transfer case with its rear face down on a flat surface.
  7. Install the differential module. Clean the components. Install the spacer.
  8. Install the clutch. Clean the components. Engage the actuator levers.
  9. Install the chain and sprocket. Clean the components.
  10. Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown. Clean the component mating faces. Clean the dowels and dowel holes. Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.
  11. Install the front half of the transfer case. Evenly tighten the 2 Torx bolts shown to 35 Nm (26 lb.ft).
  12. Tighten the remaining Torx bolts to 35 Nm (26 lb.ft).
  13. Install the shift motor. Clean the components. Tighten the Torx bolts to 25 Nm (18 lb.ft).
  14. With assistance, release the transfer case from the flat surface. Remove the 2 bolts.
  15. Install the transfer case. Refer to «Transfer Case - 5.0L»(ref-514923) or «Transfer Case - 5.0L»(ref-514869-S10896706512012112600000) .
  16. Refill the transfer case with the recommended fluid. See «Transfer Case Draining and Filling»(ref-514869-S38094148362012112600000) .
  17. Connect the battery ground cable. Refer to «Specifications»(ref-514850) article.

SPECIAL TOOL(S)

303-1069 Adaptor, Wrench

General Equipment

Transmission jack
Vehicle/axle stands
Wooden Block

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  1. Raise and support the vehicle.
  2. Refer to «TRANSMISSION SUPPORT CROSSMEMBER - (5.0L)»(ref-514849-S28264263702012112600000) .
  3. Remove the 6 Torx bolts and washers.
  4. Using a suitable tie strap, secure the driveshaft above the transfer case.
  5. General Equipment: Transmission jack General Equipment: Vehicle/axle stands General Equipment: Wooden Block
  6. Special Tool(s): 303-1069
  7. See figure.

SPECIAL TOOL(S)

303-1069 Adaptor, Wrench

General Equipment

Transmission jack
Vehicle/axle stands
Wooden Block
  1. Clean the component mating faces. Lubricate input shaft splines with 'Weicon TL7391' grease. General Equipment: Transmission jack General Equipment: Vehicle/axle stands General Equipment: Wooden Block
  2. Special Tool(s): 303-1069 Torque: 45 Nm
  3. Torque: 60 Nm
  4. Clean the component mating faces. Torque: Stage 1 44 Nm Stage 2 45°
  5. Torque: Stage 1 45 Nm Stage 2 90°
  6. Refer to «TRANSMISSION SUPPORT CROSSMEMBER - (5.0L)»(ref-514849-S28264263702012112600000) .
  7. If a new transfer case is installed, calibrate the transfer case using the diagnostic equipment.

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