Published: 08-Nov-2013

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

Transfer Case

Transfer Case Rear Output Seal (G1706919)

REMOVAL AND INSTALLATION
  • 41.20.54
  • Oil Seal - Rear Output Shaft - Renew
  • TDV8
  • 4.10
  • USED WITHINS

Special Tool(s)

E159758

204-525-1

Replacer, Drive Flange

E87692

205-726

Remover/Installer, Wheel Hub Bearing

E55697

308-637

Installer

E158795

JLR-308-927

Support Tool, Transfer Case

E158797

JLR-308-931

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 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 to avoid damage to the mating surfaces.

    E159192
    Using a soft faced mallet, release the rear casing.
  9. E159215
  10. E159213
    Locate the magnetic filter. The filter may have dropped into the front housing in the previous step.
  11. CAUTION:

    Make sure that the mating faces are clean and free of foreign material.

    Remove the sealant from the transfer case mating faces.
  12. E159193
    Remove the spacer.
  13. E159194
  14. NOTE:

    Remove as an assembly.

    E159195
  15. E159196
    Special Tool(s): JLR-308-927
  16. 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.

    E159197
    Special Tool(s): JLR-308-931
  17. CAUTIONS:

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

    • Discard the snap ring.

    E159198
    Special Tool(s): JLR-308-931
  18. E159199
  19. E159200
  20. E159201
  21. With assistance, release the transfer case from the flat surface.
Installation
CAUTION:

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

  1. E159202
    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.

    E159203
    Install the bearing.
    Special Tool(s): 205-726
  3. E159200
  4. E159204
    Install the seal.
    Special Tool(s): 308-637
  5. 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.

    E159205
    Using the special tool and with assistance, install the drive flange.
    Special Tool(s): 204-525-1
  6. With assistance, secure the rear half of the transfer case with it's rear face down on a flat surface.
  7. E159193
    Install the spacer.
  8. NOTE:

    Rotate the differential to engage the splines.

    E159206
  9. NOTE:

    Rotate the assembly to engage the clutch plates.

    E159207
  10. E159208
  11. CAUTION:

    Make sure that the front driveshaft gear bearing is fully seated before installing the chain and gear.

    E149283
  12. CAUTION:

    Make sure that the chain is installed with the dark links facing down.

    NOTE:

    The relieved splined inner diameter of the sprocket must face up as shown.

    E159209
  13. CAUTION:

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

    E159210
  14. E159211
    Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.
  15. CAUTIONS:

    • 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.

    E159212
    Install the front half of the transfer case.
  16. 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.
  17. CAUTION:

    Only tighten the bolts finger-tight at this stage.

    E159191
  18. E159409
    Torque: 10Nm
  19. E159191
    Torque: 35Nm
  20. E159190
    Torque: 35Nm
  21. E159189
    Torque: 75Nm
  22. With assistance, release the transfer case from the flat surface.
  23. 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).
  24. Refer to: Transfer Case Draining and Filling (308-07 Transfer Case, General Procedures).