Published: 08-Nov-2013

2007.0 Range Rover Sport (LS), 308-07B

Transfer Case

Transfer Case Front Output Seal (G1706917)

REMOVAL AND INSTALLATION
  • 41.20.51
  • Oil Seal - Front Output Shaft - Renew
  • TDV8
  • 4.00
  • USED WITHINS

Special Tool(s)

E55429

205-818

Installer, Seal

E159151

308-620

Installer, Seal

E55702

308-636

Installer

E158794

JLR-308-926

Support Tool, Transfer Case

E158799

JLR-308-933

Remover, Transfer Case Flange

Removal
NOTE:

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


  1. WARNING:

    Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

    Raise and support the vehicle.
  2. Refer to: Transfer Case Draining and Filling (308-07B, General Procedures).
  3. Refer to: Transfer Case - V8 S/C 4.2L Petrol (308-07B Transfer Case, Removal).
    Refer to: Transfer Case - V8 4.4L Petrol (308-07B, Removal).
    Refer to: Transfer Case - TDV6 2.7L Diesel (308-07B, Removal).
    Refer to: Transfer Case - TDV8 3.6L Diesel (308-07B, Removal).
  4. With assistance, secure the transfer case with it's transmission mating face down on a flat surface.
  5. E159189
  6. WARNING:

    Eye protection must be worn.

    CAUTION:

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

    E159190
  7. WARNING:

    Eye protection must be worn.

    CAUTION:

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

    E159191
  8. 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.
  9. CAUTION:

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

    E159214
    Using a soft faced mallet, release the front casing.
  10. Remove the sealant from the transfer case mating faces.
  11. E159216
  12. E159217
    Special Tool(s): JLR-308-926
  13. CAUTION:

    Make sure that the special tool is correctly located. This will make sure that the snap ring is fully compressed during the next step.

    E159218
    Special Tool(s): JLR-308-933
  14. CAUTIONS:

    • Do not use excessive force whilst removing the flange assembly.

    • Discard the snap ring.

    E159219
    Special Tool(s): JLR-308-933
  15. E159220
  16. E159221
Installation
CAUTION:

During the installation, make sure that all components are clean and free from foreign material.

  1. E159222
    Position the special tool as shown, to support the transfer case during the next step.
    Special Tool(s): JLR-308-926
  2. CAUTIONS:

    • The chamfer on the bearing inner track must face the seal.

    • The transfer case must be supported by the special tool on a flat surface during this step.

    E159223
    Install the bearing.
    Special Tool(s): 308-620, JLR-308-926
  3. E159224
    Install the seal.
    Special Tool(s): 308-636
  4. CAUTIONS:

    • Centralise the snap ring in the snap ring groove before installing the output flange.

    • Extreme care is necessary to make sure the snap ring enters the bearing squarely.

    • Install a new snap ring.

    E159225
    Using the special tool and with assistance, install the drive flange.
    Special Tool(s): 205-818
  5. CAUTION:

    Make sure that the oil pump is installed over its location peg.

    E159226
  6. Clean the magnetic filter.
  7. CAUTION:

    Make sure that the clutch assembly is correctly located as illustrated.

    E149289
  8. CAUTION:

    Make sure that the clutch assembly is correctly located as illustrated.

    E149286
  9. E159211
    Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.
  10. CAUTIONS:

    • Make sure that the input shaft spacer is correctly located.

    • 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.

    E159212
    Install the front half of the transfer case.
  11. 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 it's transmission mating face down on a flat surface.
  12. CAUTION:

    Only tighten the bolts finger-tight at this stage.

    E159191
  13. E159409
    Torque: 10Nm
  14. E159191
    Torque: 35Nm
  15. E159190
    Torque: 35Nm
  16. E159189
    Torque: 75Nm
  17. With assistance, release the transfer case from the flat surface.
  18. Refer to: Transfer Case - V8 S/C 4.2L Petrol (308-07B Transfer Case, Installation).
    Refer to: Transfer Case - V8 N/A 4.4L Petrol (308-07B Transfer Case, Installation).
    Refer to: Transfer Case - TDV6 2.7L Diesel (308-07B, Installation).
    Refer to: Transfer Case - TDV8 3.6L Diesel (308-07B, Installation).
  19. Refer to: Transfer Case Draining and Filling (308-07B, General Procedures).