Installing a transfer case (Defender 2007+)

Special tool(s)

	Powertrain Jack Assembly HTJ1200-02
	Transfer case support part 100-045

Materials

Name	Specification
Silicone sealant	WSE-M4G323-A4

Installation

1. Install the transfer case with your partner.

• Apply sealant to the bolt threads.
• Tighten the bolts (tightening torque 45 Nm).
• Tighten the nuts (tightening torque 45 Nm).

2.

NOTE: Lower the transmission jack.

Install the right-hand transfer case mount.

• Tighten the bolts (tightening torque 85 Nm).
• Tighten the nut (tightening torque 48 Nm).

3. Remove the special tool.





4. Remove the special tool.



5. Screw in the bolts.

• Apply sealant to the bolt threads.
• Tighten it up (tightening torque 25 Nm).

6. Secure the transmission wiring harness. Tighten (tightening torque 45 Nm).



7. Install the differential lock control rod. Tighten the nut to 25 Nm.





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8. Install the new clamp onto the lower end of the swing arm.



9.

NOTE: Make sure the rod makes full contact with the ball joint.

Connect the high/low range selector shaft.



10. Connect the differential lock detection switch electrical connector.

• 1. Connect the plug connector.
• 2. Attach the electrical connector to the bracket.

11. Connect the electrical connector of the differential lock indicator light.

• 1. Connect the plug connector.
• 2. Attach the electrical connector to the bracket.

12.

NOTE: Remove and discard plugs.

Screw in the transfer case breather tube bolt.

• Install new sealing washers.
• Tighten the bolt to 15 Nm.

13. Tighten (tightening torque 12 Nm).



14. Tighten (tightening torque 45 Nm).



15. Connect the electronic speedometer electrical connector to the transfer case.



16.

NOTE: Remove and discard the clamp.

Tighten it up (tightening torque 45 Nm). Adjust the position of the cardan shaft relative to the drive gear flange.



17.

NOTE: Install new nuts.

NOTE: Clean the drive shaft flanges and mating surfaces.

Tighten to 47 Nm (35 lbs/ft). Check the position of the cardan shaft relative to the drive gear flange.



18. Install the intermediate pipe and muffler.



19. Attach the outlet pipe to the intermediate pipe.

• Install a new gasket.
• Tighten the new nuts (tightening torque 30 Nm).

20. Secure the intermediate pipe to the catalytic converter. Install, but do not tighten, the new nuts. Tighten the new nuts to 30 Nm (22 lbs/ft).



21. Fill 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).

22. Lower the vehicle.

23. Install the parking brake lever pin. Install a new pin.

24. Attach the protective cover to the lever; parking brake. Install 3 clamps.