Transfer case extension — removal and installation (Defender 2007+)

Removal

1. Drain the oil from the transfer case.

For more information, refer to the chapter: Draining and Filling Transfer Case Transmission Fluid (308-07A Transfer Case - ID4 2.4L Diesel Engine, General Procedures).

2. Remove the transfer case secondary shaft rear seal.

For more information, refer to the chapter: Transfer Case Rear Output Shaft Seal (308-07A Transfer Case - ID4 2.4L Diesel Engine, On-Vehicle Repair).

3. Mark the position of the protruding section housing relative to the main crankcase to facilitate subsequent assembly.

(Details can be found on the website: www.lrman.ru)

4. Mark the position of the flange bolt, unscrew the 6 bolts securing the protruding section housing to the main crankcase.

Installation

1. Clean the extension section housing, the mating surface on the main case and remove any sealant from the bolt threads.

2. Apply sealant (part number STC 4600) to the secondary shaft housing mating flange.

3. Install the protruding section housing onto the main case, making sure that the secondary shaft splines engage the differential.



4. Apply sealant (part number STC 50552) to the bolt threads.

5. Screw in the bolts and tighten them in a cross sequence to 45 Nm.

6. Install the secondary shaft rear seal.

For more information, refer to the chapter: Transfer Case Rear Output Shaft Seal (308-07A Transfer Case - ID4 2.4L Diesel Engine, On-Vehicle Repair).

7. Fill the transfer case with oil.

For more information, refer to the chapter: Draining and Filling Transfer Case Transmission Fluid (308-07A Transfer Case - ID4 2.4L Diesel Engine, General Procedures).