Published: 11-Apr-2018

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

Transfer Case

Transfer Case Multiplate Clutch Assembly (G2060858)

REMOVAL AND INSTALLATION

General Equipment

Equipment name
Land Rover diagnostic equipment
Removal
NOTES:

  • If performing this procedure as part of the bulletin LTB00906, then proceed to step 7.

  • This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

  • This procedure contains illustrations showing certain components removed to provide extra clarity.


  1. Disconnect the startup battery ground cable.
    Refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).
  2. Raise and support the vehicle on a suitable 2 post lift.
    Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
    • CAUTION:

      The transfer case must be drained and filled, at least twice to make sure any debris or contaminated oil is flushed out

      Drain the transfer case oil.
      Refer to: Transfer Case Draining and Filling (308-07B Transfer Case, General Procedures).
  4. Road test the vehicle.
  5. Raise and support the vehicle on a suitable 2 post lift.
    Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  6. Drain the transfer case oil.
    Refer to: Transfer Case Draining and Filling (308-07B Transfer Case, General Procedures).
  7. Remove the transfer case.
    Refer to: Transfer Case - V8 N/A 4.4L Petrol (308-07B Transfer Case, Removal).
  8. E159189
    Remove the transfer case mass damper.
  9. E159190
    Remove the transfer case motor.
  10. E159191
    Remove the transfer case bolts.
  11. With assistance, release the transfer case and secure with its transmission mating face down on a flat surface.
  12. CAUTION:

    Care must be taken to avoid damaging the mating surfaces.

    E159214
    • Using a soft faced mallet, release the front casing.
    • Remove the breather.
  13. E159216
    Remove the input shaft and oil pump assembly.
  14. E149282
    Remove the transfer case chain assembly.
  15. E201513
    Remove the transfer case multiplate clutch assembly.
  16. E201540
    Remove the transfer case differential assembly.
  17. CAUTION:

    Make sure there is no debris or contaminated oil remaining in the transfer case. Do not use water based solvent.

    NOTE:

    Use a lint free cloth to absorb any residue of contaminated oil remaining in the transfer case.

    Clean the transfer case and components thoroughly.
Installation
  1. CAUTION:

    The magnet may be loose in the transfer case, make sure it is correctly located.

    E159210
    Install the magnet, If required.
  2. CAUTION:

    Make sure that the input shaft spacer is correctly located.

    E201517
  3. E201541
    Install the transfer case differential assembly.
  4. NOTE:

    This step requires the aid of another technician.

    E201515
    • Install the transfer case multiplate clutch assembly.
    • Using a suitable tool, open the levers as illustrated.
    • With the transfer case levers open, locate the transfer case multiplate clutch into the differential assembly.
  5. CAUTION:

    Make sure the multiplate clutch assembly is correctly installed.

    E201516
    The teeth of the multiplate clutch assembly will not be visible if correctly installed.
  6. CAUTION:

    Make sure that the transfer case chain is installed with the transfer case chain link facing down.

    E149284
    Install the transfer case chain assembly
  7. E159211
    • Apply RTV sealant in a 2 mm bead to one surface of the transfer case mating faces as illustrated.
    • For the correct specification of sealant.
      Refer to: Specifications (308-07B Transfer Case, Specifications).
  8. CAUTIONS:

    • Make sure the breather is correctly located.

    • Make sure the input shaft roller bearing is not damaged.

    E201518
    • Inspect the roller bearing for damage.
    • Install the breather.
  9. CAUTION:

    The input shaft and transfer case oil pump assembly must be supported and held in place by hand, until it is located securely into the transfer case clutch assembly.

    E201519
    Install the front half of the transfer case.
  10. CAUTION:

    Care must be taken when turning the transfer case over. The transfer case halves must not be allowed to separate.

  11. E159191
    Tighten the bolts finger-tight at this stage.
  12. E159409
    • Tighten the bolts.
    • Torque: 10Nm
  13. E159191
    • Tighten the bolts.
    • Torque: 35Nm
  14. E159190
    • Install the transfer case motor.
    • Torque: 35Nm
  15. E159189
    • Install the transfer case mass damper.
    • Torque: 75Nm
  16. Install the transfer case.
    Refer to: Transfer Case - TDV8 3.6L Diesel (308-07B Transfer Case, Installation).
  17. Fill the transfer case with oil.
    Refer to: Transfer Case Draining and Filling (308-07B Transfer Case, General Procedures).
  18. Reconnect the battery ground cable.
    Refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  19. Use the approved Land Rover diagnostic equipment to configure the transfer case control module.
    General Equipment: Land Rover diagnostic equipment
  20. CAUTION:

    The vehicle should be driven through at least 4 tight turns either left or right in high and low range drive. Failure to follow this instruction could result in a failed calibration.

    Road test the vehicle.
  21. CAUTION:

    The transfer case control module must be calibrated again to achieve a successful bedding in procedure.

    Use the approved Land Rover diagnostic equipment to configure the transfer case control module.
    General Equipment: Land Rover diagnostic equipment