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Transfer Case Land Rover Range Rover L322

Automatic Trans 43 illustrations ~1720 words

SPECIFICATIONS

ItemSpecification
* Recommended oilShell TF 0753
Capacity - Wet and dry fill1.5 liters, (2.6 pints) (1.5 US quarts)
Input shaft splines greaseWeicon TL7391

SEALERS AND LUBRICANTS

CAUTION* Do not use any lubricant other than that specified
ItemSpecification
MakeMagna Steyr
ModelDD295
TypeTwo speed, permanent four wheel drive transfer box having synchronized shift on the move facility with an actively controlled wet clutch and 50/50 torque split across the center differential
Clutch typeWet, multi-plate
Maximum torque capacity2500 Nm (1842.5 lb-ft)
Ratios
High1:1
Low2.93:1
Maximum shift speeds
High to low ratio40 kph (24.8 mph)
Low to high ratio60 kph (37.2 mph)
DescriptionNm
Transfer case fluid drain plug22
Transfer case fluid filler/level plug22
Transmission support insulator to transfer case bolts60
Transfer case to transmission bolts45
* Front driveshaft to transfer case output flange
Stage 145
Stage 2Further 90°

TORQUE SPECIFICATIONS

* New 'patched' Torx bolts must be installed

PRINCIPLE OF OPERATION

For a detailed description of the transfer case system and operation, refer to the relevant Description and Operation section of the workshop manual.

INSPECTION AND VERIFICATION

CAUTIONDiagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION Mechanical Electrical Transfer case Oil leaks Driveshafts Halfshafts Constant velocity (CV) joints Fuse(s) Wiring harness/electrical connectors Controller area network (CAN) circuits Instrument cluster Range change selection switch Transfer case control module
  3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.

SYMPTOM CHART

SymptomMessagePossible CausesAction
Loss of drive due to transfer case stuck in neutral and transmission park lock function is inoperative'PARK LOCK FAILURE APPLY HANDBRAKE'Transfer case control module CAN bus - off bus during range change Transfer case changeover solenoid fault Transfer case motor fault Transfer case internal obstructionCheck for Transfer Case Control Module DTCs and refer to the relevant DTC Index
Loss of driveHalf shaft failure Driveshaft failure Front or rear axle: differential failure Transfer case center differential failureCheck the condition of the driveshafts, half shafts and CV joints, differential
Range change inhibited'TRANSMISSION RANGE CHANGE INOPERATIVE'Transfer case control module has shut down due to thermal overload Transfer case internal obstruction Transfer case changeover solenoid fault Transfer case motor fault Transfer case control module failureCheck for Transfer Case Control Module DTCs and refer to the relevant DTC Index
Off road traction reduced'TRANSMISSION OVER HEAT SLOW DOWN'Center differential temperature is approaching the over heated thresholdCheck for over-temperature DTCs
'TRANSMISSION FAULT - TRACTION REDUCED'Center differential has failed - operating as an open differential Transfer case control module has stopped transmitting on the CAN bus and defaults to open center differentialCheck for lost communication and bus off DTCs

DTC INDEX

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00. Refer to Refer to Diagnostic Trouble Code (DTC) Index - DTC: Module Name: Transfer Case Control Module article.

ALL VEHICLES

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Scheme 25: TRANSFER CASE DRAINING AND FILLING
Scheme 25: TRANSFER CASE DRAINING AND FILLING

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  1. Raise and support the vehicle.
  2. Position a container to collect the fluid.
  3. Remove the fluid drain plug. Clean the immediate area. Remove and discard the sealing washer.
  4. Remove the fluid drain plug. Clean the immediate area. Remove and discard the sealing washer.
  5. Allow the fluid to drain.
  6. Install the drain plug and tighten it to 22 Nm (16 lb.ft). Clean the component mating faces. Install a new sealing washer.
  7. Install the drain plug and tighten it to 25 Nm (18 lb.ft). Clean the component mating faces. Install a new sealing washer.
  8. Remove the fluid filler/level plug. Clean the immediate area. Remove and discard the sealing washer.
  9. Remove the fluid filler/level plug. Clean the immediate area. Remove and discard the sealing washer.
  10. Refill transfer case with the recommended fluid, until the fluid is level with bottom of filler/level plug hole.
  11. Install the fluid filler/level plug and tighten to 22 Nm (16 lb.ft). Clean the component mating faces. Install a new sealing washer.
  12. Install the fluid filler/level plug and tighten to 25 Nm (18 lb.ft). Clean the component mating faces. Install a new sealing washer.

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Oil seal installer 308-598 Slide hammer 100-012 Slide hammer adaptor 100-012-01 Seal remover input and output 308-375

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Scheme 29: TRANSFER CASE INPUT SHAFT SEAL (5.0L NA V8 - AJ133/5.0L SC V8 - AJ133)
Scheme 29: TRANSFER CASE INPUT SHAFT SEAL (5.0L NA V8 - AJ133/5.0L SC V8 - AJ133)

REMOVAL

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

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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»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#four-wheel-drive-systems) or See «Transfer Case - 5.0L NA V8 - AJ133/5.0L SC V8 - AJ133»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  3. Carefully remove and discard the oil seal. Use the special tools.

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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»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) . .

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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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»(/land-rover/range-rover/l322-2009-2012/remont/charging-system/#battery-and-charging-system-general-information) article.
  2. Raise and support the vehicle.
  3. Drain the transfer case fluid. See «Transfer Case Draining and Filling»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  4. Remove the transfer case. Refer to «Transfer Case - 5.0L»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#four-wheel-drive-systems) or See «Transfer Case - 5.0L»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  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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  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»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#four-wheel-drive-systems) or «Transfer Case - 5.0L»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  15. Refill the transfer case with the recommended fluid. See «Transfer Case Draining and Filling»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  16. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2009-2012/remont/charging-system/#battery-and-charging-system-general-information) article.

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

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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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  1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2009-2012/remont/charging-system/#battery-and-charging-system-general-information) article.
  2. Raise and support the vehicle.
  3. Drain the transfer case fluid. See «Transfer Case Draining and Filling»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  4. Remove the transfer case. Refer to «Transfer Case - 5.0L»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#four-wheel-drive-systems) or See «Transfer Case - 5.0L»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  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.

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Scheme 54: INSTALLATION
Scheme 54: INSTALLATION

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  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»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#four-wheel-drive-systems) or «Transfer Case - 5.0L»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  16. Refill the transfer case with the recommended fluid. See «Transfer Case Draining and Filling»(/land-rover/range-rover/l322-2009-2012/remont/automatic-trans/#transfer-case) .
  17. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2009-2012/remont/charging-system/#battery-and-charging-system-general-information) 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)»(/land-rover/range-rover/l322-2009-2012/remont/frames-subframes-crossmembers/#full-frame-and-body-mounting) .
  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)»(/land-rover/range-rover/l322-2009-2012/remont/frames-subframes-crossmembers/#full-frame-and-body-mounting) .
  7. If a new transfer case is installed, calibrate the transfer case using the diagnostic equipment.

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