Land Rover 2000-05

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Radiator fan shroud
     
    Transfer case shift knob and boot
     
    Transfer case fluid
     
    Heat shield from the front exhaust pipe
     
    Catalytic converter assembly
     
    Crossmember from under the transfer case
     
    Speedometer cable and tie it out of the way
     

  4.  
  5. Matchmark the front and rear driveshafts-to-flanges relation.
  6.  
  7. Disconnect the front and rear driveshafts and tie them out of the way.
  8.  
  9. Secure an adapter plate LRT-99-010.
  10.  
  11. Place 4 1316
  12.  
  13. Remove the 4 central bolts from the transfer case and secure the hoist with the adapter plate to the unit.
  14.  
  15. Raise the hoist to take the weight off the transfer case.
  16.  
  17. Remove the left and right transfer case rubber mounts.
  18.  
  19. Slowly lower the hoist until the park brake drum clears the passenger footwell. Be sure the engine does not crush any components.
  20.  
  21. Loosen the park brake adjustment nut and remove the park brake drum assembly from the rear output flange.
  22.  
  23. Label and unplug all sensors and switches from the transfer case.
  24.  
  25. Remove the transfer case breather banjo bolt and position it aside.
  26.  
  27. Disconnect the differential lock engaging rod.
  28.  
  29. Place the transfer case in low range.
  30.  
  31. Remove the range selector rod lower nut, then the rod from the yoke.
  32.  
  33. Support the transmission with a wooden block.
  34.  
  35. Remove the upper and lower transfer case mounting bolts.
  36.  
  37. Fit guide studs 18G 1425 to the transmission and move the transfer case rearward to remove.
  38.  


    Click image to see an enlarged view

    Fig. Location of the 4 central bolts-mount the adapter plate after removing these bolts-Discovery (2001-04)


To install:

  1. Be sure the mating surface of the transmission and transfer case is free from dirt and debris.
  2.  
  3. Raise the transfer case until it is located over the guide studs 18G 1425, then slide it forward onto the transmission.
  4.  
  5. Remove the guide studs and bolt the transfer case to the transmission.
  6.  
  7. Complete the installation procedure in the reverse order of the removal procedure, noting the following items:

    After removing the adapter plate, clean the 4 bottom cover bolts and coat them with Loctite ® 290, then tighten to 19 ft. lbs. (25 Nm).
     
    Fill the transfer case with 90W oil.
     
    Check and adjust the park brake cable.
     

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground cable.
  4.  
  5. Remove front exhaust pipe.
  6.  
  7. Drain transfer case oil.
  8.  
  9. Remove 8 bolts securing rear crossmember and remove crossmember.
  10.  
  11. Remove intermediate muffler from tail pipe and from rubber mounts.
  12.  
  13. Remove front and rear propeller shafts.
  14.  
  15. Remove parking brake drum.
  16.  
  17. Remove parking brake backing plate and tie aside.
  18.  
  19. On models with high/low shift interlock solenoid, disconnect solenoid connector from main harness. Also, remove sleeve retaining rings and remove sleeve from high/low selector cable.
  20.  
  21. Release and remove clevis pin holding differential lock selector cable to transfer case.
  22.  
  23. Loosen locknuts holding differential lock selector cable to bracket, and remove cable.
  24.  
  25. Remove clevis pin securing high/low ratio selector cable to selector lever. Remove C-clip and release outer cable from bracket.
  26.  
  27. Remove clevis pin and C-washer holding high/low ratio selector cable to selector lever. Release cable from bracket.
  28.  
  29. Remove 2 cable ties securing cable to fuel pipes.
  30.  
  31. If fitted, disconnect 2 Lucar connectors from oil temperature sensor and disconnect reverse lamp switch connector.
  32.  
  33. Remove banjo bolt securing breather pipe and discard washers.
  34.  
  35. If fitted, disconnect 2 Lucar connectors from differential lock switch.
  36.  
  37. Disconnect multiplug from reverse light switch.
  38.  
  39. If fitted, disconnect both differential lock warning lamp switch connectors from main harness.
  40.  
  41. Release and disconnect transfer case neutral switch connector.
  42.  
  43. Remove 4 bolts from transfer case bottom plate, then position support plate LRT-99-010 to transfer case and tighten bolts.
  44.  
  45. Position transmission support jack and secure support plate LRT-99-010 to jack with 4 bolts.
  46.  
  47. Remove 3 transfer case-to-transmission bolts and install 3 guide studs LRT-41-009 through transfer case bolt holes for support during removal.
  48.  
  49. Remove 2 bolts and 1 nut securing transfer case to transmission.
  50.  


    Click image to see an enlarged view

    Fig. Showing transfer case support plate LRT-99-010 installed-Discovery (2003-04)



    Click image to see an enlarged view

    Fig. Installed positions of guide studs-Discovery (2003-04)



CAUTION
If securing stud is removed during this operation, it must be discarded and a new stud fitted.

  1. Position a jack to support transmission and engine.
  2.  
  3. Remove 4 bolts and nut from right side transfer case mount.
  4.  
  5. Remove nut from left side transfer case mount.
  6.  
  7. Raise transmission slightly and remove right side mount.
  8.  
  9. Remove transfer case input shaft oil seal.
  10.  

To install:

  1. Install a new transfer case input shaft oil seal.
  2.  
  3. Clean transfer case-to-transmission mating faces.
  4.  
  5. Raise transfer case on jack and align to guide studs LRT-41-099.
  6.  
  7. Clean transfer case mounting bolt threads and apply sealant to bolt and stud threads.
  8.  
  9. Fit and lightly tighten 2 bolts and nut securing transfer case to transmission.
  10.  


NOTE
If a new stud is fitted, apply sealant STC 50552 to stud threads and tighten to 33 ft. lbs. (45 Nm).

  1. Remove guide studs, a replace them with 3 bolts, lightly tightened.
  2.  
  3. Tighten all transfer case-to-transmission bolts, in a diagonal pattern, to 33 ft. lbs. (45 Nm).
  4.  
  5. Position transmission right side mount and tighten bolts to 63 ft. lbs. (85 Nm).
  6.  
  7. Tighten right side mount nut to 35 ft. lbs. (48 Nm).
  8.  
  9. Remove 4 bolts securing support plate to transmission jack. Remove support plate-to-transfer case bolts and remove plate.
  10.  
  11. Clean threads of bottom plate bolts. Apply sealant STC 50552 to threads.
  12.  
  13. Install and tighten bottom plate bolts to 18 ft. lbs. (25 Nm).
  14.  
  15. Using new washers, position breather pipe and tighten banjo bolt.
  16.  
  17. Connect multiplug to transfer case neutral switch and secure harness.
  18.  
  19. If fitted, connect Lucar connectors to differential lock switch.
  20.  
  21. If fitted, connect differential lock warning lamp connectors and secure harness.
  22.  
  23. Attach connector to reverse lamp switch.
  24.  
  25. If fitted, connect Lucar connectors to oil temperature switch.
  26.  
  27. Position high/low ratio selector cable and secure with C-washer and clevis pin.
  28.  
  29. Position differential lock selector cable to bracket and tighten locknuts sufficiently to retain cable.
  30.  
  31. Fit selector cable to transfer case and secure with clevis pin. Adjust cable.
  32.  
  33. If fitted with high/low shift interlock solenoid, position solenoid harness to shift cable, fit sleeve around cable and harness, and secure sleeve, then connect multiplug to main harness and secure to bracket.
  34.  
  35. With new cable ties, attach cable to fuel pipes.
  36.  
  37. Clean parking brake backing plate and mating face. Install plate and tighten bolts to 55 ft. lbs. (75 Nm).
  38.  
  39. Clean parking brake drum, then install and tighten retaining screw.
  40.  
  41. Install rear then front propeller shafts.
  42.  
  43. Install intermediate muffler, using new gasket. Tighten nuts to 18 ft. lbs. (25 Nm).
  44.  
  45. Install rear crossmember and tighten bolts to 19 ft. lbs. (26 Nm).
  46.  
  47. Refill transfer case.
  48.  
  49. Install front exhaust pipe.
  50.  
  51. Reconnect battery ground cable.
  52.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Window switch pack
     
    Hand brake cable clevis pin
     
    Transmission and transfer case fluids
     
    Front exhaust pipes from the manifolds
     
    Hand brake cable from the grommet in the tunnel
     
    Rear driveshaft shaft guard
     
    Driveshafts
     
    Gear selector cable from the transmission lever, then from the cable bracket.
     
    Transfer case fluid temperature sensor electrical connector
     
    High/Low motor and output shaft speed sensor electrical connectors
     

  4.  
  5. Attach a suitable transmission jack to the transfer case.
  6.  
  7. Remove the 6 transfer case-to-transmission mounting bolts.
  8.  
  9. Lower the transfer case form the vehicle.
  10.  
  11. Using a suitable seal removal tool, remove the transmission output seal.
  12.  


    Click image to see an enlarged view

    Fig. Transfer case bolt locations-Range Rover (2001-02)


To install:

  1. Install a new transmission output seal, using a suitable seal installer.
  2.  
  3. Ensure transfer case and transmission mating faces are clean.
  4.  
  5. Lubricate the input shaft with transmission fluid.
  6.  
  7. Install the transfer case and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Remove the transmission jack.
  10.  
  11. Install or connect the following:

    High/Low motor and output shaft speed sensor electrical connectors
     
    Transfer case fluid temperature sensor electrical connector
     
    Gear selector cable
     
    Driveshafts, align the matchmarks and tighten the mounting bolts to 35 ft. lbs. (48 Nm).
     
    Driveshaft guard
     
    Hand brake cable through the grommet in the transmission tunnel
     
    Exhaust system
     
    Transmission and transfer case fluid
     
    Handbrake cable
     
    Window switch pack
     
    Negative battery cable
     

  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Transfer case fluid
     
    Cooling fan
     
    Front and rear driveshafts
     
    Right side heat shield
     
    Support transmission on a suitable jack
     
    Crossmember
     
    Snubbers
     
    Lower transmission for access
     
    High/low shift motor connector
     
    Breather hose
     
    Oxygen sensor connectors
     
    Support transfer case with suitable jack
     
    9 transfer case mounting bolts
     
    Lower transfer case
     

  4.  

To install:

  1. Ensure transfer case and transmission mating faces are clean.
  2.  
  3. Lubricate the input shaft with anti-sieze.
  4.  
  5. Install the transfer case and tighten the mounting bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Remove the transmission jack.
  8.  
  9. Install or connect the following:

    Oxygen sensor connectors
     
    Breather hose
     
    High/low shift motor connector
     
    Snubbers
     
    Crossmember, but do not tighten bolts
     
    Raise transmission
     
    Align crossmember and tighten bolts to 50 ft. lbs. (68 Nm).
     
    Remove jack
     
    Right side heat shield
     
    Front and rear driveshafts
     
    Cooling fan
     
    Transfer case fluid
     

  10.  
  11. Start vehicle and check for leaks.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Radiator fan shroud

    Click image to see an enlarged view

    Fig. Remove the fan shroud to prevent the fan from damaging it-Discovery models



    Click image to see an enlarged view

    Fig. Be sure to support the transmission before removing the crossmember bolts-Discovery models

     
    Transfer case shift knob and boot
     
    Transfer case fluid
     
    Heat shield from the front exhaust pipe
     
    Catalytic converter assembly
     
    Crossmember from under the transfer case
     
    Speedometer cable and tie it out of the way
     

  4.  
  5. Matchmark the front and rear driveshafts-to-flanges relation.
  6.  
  7. Disconnect the front and rear driveshafts and tie them out of the way.
  8.  
  9. Construct an adapter plate for removing the transfer case, as indicated in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Dimensions for the adapter plate-Discovery



    Click image to see an enlarged view

    Fig. Location of the 4 central bolts-mount the adapter plate after removing these bolts-Discovery

  10.  
  11. Place 4 1 3 / 16 in. (30mm) spacers between the top of the hoist and the adapter plate, then secure the plate to the hoist.
  12.  
  13. Remove the 4 central bolts from the transfer case and secure the hoist with the adapter plate to the unit.
  14.  
  15. Raise the hoist to take the weight off the transfer case.
  16.  
  17. Remove the left and right transfer case rubber mounts.
  18.  
  19. Slowly lower the hoist until the park brake drum clears the passenger footwell. Be sure the engine does not crush any components.
  20.  
  21. Loosen the park brake adjustment nut and remove the park brake drum assembly from the rear output flange.
  22.  
  23. Label and unplug all sensors and switches from the transfer case.
  24.  
  25. Remove the transfer case breather banjo bolt and position it aside.
  26.  
  27. Disconnect the differential lock engaging rod.
  28.  
  29. Place the transfer case in low range.
  30.  
  31. Remove the range selector rod lower nut, then the rod from the yoke.
  32.  
  33. Support the transmission with a wooden block.
  34.  
  35. Remove the upper and lower transfer case mounting bolts.
  36.  
  37. Fit guide studs 18G 1425 to the transmission and move the transfer case rearward to remove.
  38.  

To install:

  1. Be sure the mating surface of the transmission and transfer case is free from dirt and debris.
  2.  
  3. Raise the transfer case until it is located over the guide studs 18G 1425, then slide it forward onto the transmission.
  4.  
  5. Remove the guide studs and bolt the transfer case to the transmission.
  6.  
  7. Complete the installation procedure in the reverse order of the removal procedure, noting the following items:

    After removing the adapter plate, clean the 4 bottom cover bolts and coat them with Loctite ® 290, then tighten to 19 ft. lbs. (25 Nm).
     
    Fill the transfer case with 90W oil.
     
    Check and adjust the park brake cable.
     

  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Window switch pack
     
    Hand brake cable clevis pin
     
    Transmission and transfer case fluids
     
    Front exhaust pipes from the manifolds
     
    Hand brake cable from the grommet in the tunnel
     
    Rear driveshaft shaft guard
     
    Driveshafts
     
    Gear selector cable from the transmission lever, then from the cable bracket.
     
    Transfer case fluid temperature sensor electrical connector
     
    High/Low motor and output shaft speed sensor electrical connectors
     

  4.  
  5. Attach a suitable transmission jack to the transfer case.
  6.  
  7. Remove the 6 transfer case-to-transmission mounting bolts.
  8.  
  9. Lower the transfer case form the vehicle.
  10.  
  11. Using a suitable seal removal tool, remove the transmission output seal.

    Click image to see an enlarged view

    Fig. Transfer case bolt locations-Range Rover

  12.  

To install:

  1. Install a new transmission output seal, using a suitable seal installer.
  2.  
  3. Ensure transfer case and transmission mating faces are clean.
  4.  
  5. Lubricate the input shaft with transmission fluid.
  6.  
  7. Install the transfer case and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Remove the transmission jack.
  10.  
  11. Install or connect the following:

    High/Low motor and output shaft speed sensor electrical connectors
     
    Transfer case fluid temperature sensor electrical connector
     
    Gear selector cable
     
    Driveshafts, align the matchmarks and tighten the mounting bolts to 35 ft. lbs. (48 Nm).
     
    Driveshaft guard
     
    Hand brake cable through the grommet in the transmission tunnel
     
    Exhaust system
     
    Transmission and transfer case fluid
     
    Handbrake cable
     
    Window switch pack
     
    Negative battery cable
     

  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Radiator fan shroud
     
    Transfer case shift knob and boot
     
    Transfer case fluid
     
    Heat shield from the front exhaust pipe
     
    Catalytic converter assembly
     
    Crossmember from under the transfer case
     
    Speedometer cable and tie it out of the way
     

  4.  
  5. Matchmark the front and rear driveshafts-to-flanges relation.
  6.  
  7. Disconnect the front and rear driveshafts and tie them out of the way.
  8.  
  9. Secure an adapter plate LRT-99-010.

    Click image to see an enlarged view

    Fig. Location of the 4 central bolts-mount the adapter plate after removing these bolts-Discovery (2000-04)

  10.  
  11. Place 4 1 3 / 16 in. (30mm) spacers between the top of the hoist and the adapter plate, then secure the plate to the hoist.
  12.  
  13. Remove the 4 central bolts from the transfer case and secure the hoist with the adapter plate to the unit.
  14.  
  15. Raise the hoist to take the weight off the transfer case.
  16.  
  17. Remove the left and right transfer case rubber mounts.
  18.  
  19. Slowly lower the hoist until the park brake drum clears the passenger footwell. Be sure the engine does not crush any components.
  20.  
  21. Loosen the park brake adjustment nut and remove the park brake drum assembly from the rear output flange.
  22.  
  23. Label and unplug all sensors and switches from the transfer case.
  24.  
  25. Remove the transfer case breather banjo bolt and position it aside.
  26.  
  27. Disconnect the differential lock engaging rod.
  28.  
  29. Place the transfer case in low range.
  30.  
  31. Remove the range selector rod lower nut, then the rod from the yoke.
  32.  
  33. Support the transmission with a wooden block.
  34.  
  35. Remove the upper and lower transfer case mounting bolts.
  36.  
  37. Fit guide studs 18G 1425 to the transmission and move the transfer case rearward to remove.
  38.  

To install:

  1. Be sure the mating surface of the transmission and transfer case is free from dirt and debris.
  2.  
  3. Raise the transfer case until it is located over the guide studs 18G 1425, then slide it forward onto the transmission.
  4.  
  5. Remove the guide studs and bolt the transfer case to the transmission.
  6.  
  7. Complete the installation procedure in the reverse order of the removal procedure, noting the following items:

    After removing the adapter plate, clean the 4 bottom cover bolts and coat them with Loctite ® 290, then tighten to 19 ft. lbs. (25 Nm).
     
    Fill the transfer case with 90W oil.
     
    Check and adjust the park brake cable.
     

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground cable.
  4.  
  5. Remove front exhaust pipe.
  6.  
  7. Drain transfer case oil.
  8.  
  9. Remove 8 bolts securing rear crossmember and remove crossmember.
  10.  
  11. Remove intermediate muffler from tail pipe and from rubber mounts.
  12.  
  13. Remove front and rear propeller shafts.
  14.  
  15. Remove parking brake drum.
  16.  
  17. Remove parking brake backing plate and tie aside.
  18.  
  19. On models with high/low shift interlock solenoid, disconnect solenoid connector from main harness. Also, remove sleeve retaining rings and remove sleeve from high/low selector cable.
  20.  
  21. Release and remove clevis pin holding differential lock selector cable to transfer case.
  22.  
  23. Loosen locknuts holding differential lock selector cable to bracket, and remove cable.
  24.  
  25. Remove clevis pin securing high/low ratio selector cable to selector lever. Remove C-clip and release outer cable from bracket.
  26.  
  27. Remove clevis pin and C-washer holding high/low ratio selector cable to selector lever. Release cable from bracket.
  28.  
  29. Remove 2 cable ties securing cable to fuel pipes.
  30.  
  31. If equipped, disconnect 2 Lucar connectors from oil temperature sensor and disconnect reverse lamp switch connector.
  32.  
  33. Remove banjo bolt securing breather pipe and discard washers.
  34.  
  35. If equipped, disconnect 2 Lucar connectors from differential lock switch.
  36.  
  37. Detach the connector from reverse light switch.
  38.  
  39. If equipped, disconnect both differential lock warning lamp switch connectors from main harness.
  40.  
  41. Release and disconnect transfer case neutral switch connector.
  42.  
  43. Remove 4 bolts from transfer case bottom plate, then position support plate LRT-99-010 to transfer case and tighten bolts.
  44.  
  45. Position transmission support jack and secure support plate LRT-99-010 to jack with 4 bolts.

    Click image to see an enlarged view

    Fig. Showing transfer case support plate LRT-99-010 installed-Discovery (2003-04)

  46.  
  47. Remove 3 transfer case-to-transmission bolts and install 3 guide studs LRT-41-009 through transfer case bolt holes for support during removal.

    Click image to see an enlarged view

    Fig. Installed positions of guide studs-Discovery (2003-04)

  48.  
  49. Remove 2 bolts and 1 nut securing transfer case to transmission.
    CAUTION
    If securing stud is removed during this operation, it must be discarded and a new stud fitted.

  50.  
  51. Position a jack to support transmission and engine.
  52.  
  53. Remove 4 bolts and nut from right side transfer case mount.
  54.  
  55. Remove nut from left side transfer case mount.
  56.  
  57. Raise transmission slightly and remove right side mount.
  58.  
  59. Remove transfer case input shaft oil seal.
  60.  

To install:

  1. Install a new transfer case input shaft oil seal.
  2.  
  3. Clean transfer case-to-transmission mating faces.
  4.  
  5. Raise transfer case on jack and align to guide studs LRT-41-099.
  6.  
  7. Clean transfer case mounting bolt threads and apply sealant to bolt and stud threads.
  8.  
  9. Fit and lightly tighten 2 bolts and nut securing transfer case to transmission.
    NOTE
    If a new stud is fitted, apply sealant STC 50552 to stud threads and tighten to 33 ft. lbs. (45 Nm).

  10.  
  11. Remove guide studs, a replace them with 3 bolts, lightly tightened.
  12.  
  13. Tighten all transfer case-to-transmission bolts, in a diagonal pattern, to 33 ft. lbs. (45 Nm).
  14.  
  15. Position transmission right side mount and tighten bolts to 63 ft. lbs. (85 Nm).
  16.  
  17. Tighten right side mount nut to 35 ft. lbs. (48 Nm).
  18.  
  19. Remove 4 bolts securing support plate to transmission jack. Remove support plate-to-transfer case bolts and remove plate.
  20.  
  21. Clean threads of bottom plate bolts. Apply sealant STC 50552 to threads.
  22.  
  23. Install and tighten bottom plate bolts to 18 ft. lbs. (25 Nm).
  24.  
  25. Using new washers, position breather pipe and tighten banjo bolt.
  26.  
  27. Connect multiplug to transfer case neutral switch and secure harness.
  28.  
  29. If equipped, connect Lucar connectors to differential lock switch.
  30.  
  31. If equipped, connect differential lock warning lamp connectors and secure harness.
  32.  
  33. Attach connector to reverse lamp switch.
  34.  
  35. If equipped, connect Lucar connectors to oil temperature switch.
  36.  
  37. Position high/low ratio selector cable and secure with C-washer and clevis pin.
  38.  
  39. Position differential lock selector cable to bracket and tighten locknuts sufficiently to retain cable.
  40.  
  41. Fit selector cable to transfer case and secure with clevis pin. Adjust cable.
  42.  
  43. If equipped with high/low shift interlock solenoid, position solenoid harness to shift cable, fit sleeve around cable and harness, and secure sleeve, then connect multiplug to main harness and secure to bracket.
  44.  
  45. With new cable ties, attach cable to fuel pipes.
  46.  
  47. Clean parking brake backing plate and mating face. Install plate and tighten bolts to 55 ft. lbs. (75 Nm).
  48.  
  49. Clean parking brake drum, then install and tighten retaining screw.
  50.  
  51. Install rear then front propeller shafts.
  52.  
  53. Install intermediate muffler, using new gasket. Tighten nuts to 18 ft. lbs. (25 Nm).
  54.  
  55. Install rear crossmember and tighten bolts to 19 ft. lbs. (26 Nm).
  56.  
  57. Refill transfer case.
  58.  
  59. Install front exhaust pipe.
  60.  
  61. Reconnect battery ground cable.
  62.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Window switch pack
     
    Hand brake cable clevis pin
     
    Transmission and transfer case fluids
     
    Front exhaust pipes from the manifolds
     
    Hand brake cable from the grommet in the tunnel
     
    Rear driveshaft shaft guard
     
    Driveshafts
     
    Gear selector cable from the transmission lever, then from the cable bracket.
     
    Transfer case fluid temperature sensor electrical connector
     
    High/Low motor and output shaft speed sensor electrical connectors
     

  4.  
  5. Attach a suitable transmission jack to the transfer case.
  6.  
  7. Remove the 6 transfer case-to-transmission mounting bolts.
  8.  
  9. Lower the transfer case form the vehicle.
  10.  
  11. Using a suitable seal removal tool, remove the transmission output seal.

    Click image to see an enlarged view

    Fig. Transfer case bolt locations-Range Rover (2000-02)

  12.  

To install:

  1. Install a new transmission output seal, using a suitable seal installer.
  2.  
  3. Ensure transfer case and transmission mating faces are clean.
  4.  
  5. Lubricate the input shaft with transmission fluid.
  6.  
  7. Install the transfer case and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Remove the transmission jack.
  10.  
  11. Install or connect the following:

    High/Low motor and output shaft speed sensor electrical connectors
     
    Transfer case fluid temperature sensor electrical connector
     
    Gear selector cable
     
    Driveshafts, align the matchmarks and tighten the mounting bolts to 35 ft. lbs. (48 Nm).
     
    Driveshaft guard
     
    Hand brake cable through the grommet in the transmission tunnel
     
    Exhaust system
     
    Transmission and transfer case fluid
     
    Parking brake cable
     
    Window switch pack
     
    Negative battery cable
     

  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Transfer case fluid
     
    Cooling fan
     
    Front and rear driveshafts
     
    Right side heat shield
     
    Support transmission on a suitable jack
     
    Crossmember
     
    Snubbers
     
    Lower transmission for access
     
    High/low shift motor connector
     
    Breather hose
     
    Oxygen sensor connectors
     
    Support transfer case with suitable jack
     
    9 transfer case mounting bolts
     
    Lower transfer case
     

  4.  

To install:

  1. Ensure transfer case and transmission mating faces are clean.
  2.  
  3. Lubricate the input shaft with anti-seize.
  4.  
  5. Install the transfer case and tighten the mounting bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Remove the transmission jack.
  8.  
  9. Install or connect the following:

    Oxygen sensor connectors
     
    Breather hose
     
    High/low shift motor connector
     
    Snubbers
     
    Crossmember, but do not tighten bolts
     
    Raise transmission
     
    Align crossmember and tighten bolts to 50 ft. lbs. (68 Nm).
     
    Remove jack
     
    Right side heat shield
     
    Front and rear driveshafts
     
    Cooling fan
     
    Transfer case fluid
     

  10.  
  11. Start vehicle and check for leaks.
  12.  

 
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