Removal the transfer case (Defender 2007+)

Special tool(s)

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

Removal

1. Release the parking brake lever protective boot. Release the 3 clamps.



2. Remove the parking brake lever pin. Unscrew the stud.



3.

WARNING: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise and support the vehicle.

4. Disconnect the intermediate pipe from the catalytic converter. Unscrew and discard the 2 nuts.



5. Release the outlet pipe from the intermediate pipe.

• Unscrew and discard 3 nuts.
• Remove the gasket and discard it.

6. Remove the intermediate pipe and muffler.



7.

NOTE: Mark the position of the front propeller shaft in relation to the transfer case drive flange.

Remove and discard the 4 nuts. Use a suitable clamp to secure the driveshaft to the side.



8. Remove the 4 nuts securing the rear propeller shaft to the transfer case. Mark the position of the propeller shaft relative to the pinion flange.



9. Using a suitable clamp, secure the rear driveshaft to the chassis.



10. Disconnect the electronic speedometer electrical connector from the transfer case.





11. Disconnect the left-hand ground cable from the transfer case. Remove the nut.



12. Disconnect the right-hand ground cables from the transfer case. Remove the bolt.



13.

NOTE: Plug all holes. Use new plugs.

Remove the bolt of the transfer case breather tube. Remove the sealing washers and discard them as no longer needed.





14. Disconnect the transmission range switch indicator light electrical connector.

• 1. Disconnect the electrical connector.
• 2. Release the electrical connector from the bracket.

15. Disconnect the differential lock detection switch electrical connector.

• 1. Disconnect the electrical connector.
• 2. Release the electrical connector from the bracket.

16. Disconnect the transmission range selector rod. To release the installed parts, press the button before disconnecting the rod.





17. Release the clamp at the lower end of the pivot arm.



18. Remove the differential lock control rod. Remove the nut.



19. Disconnect the transmission wiring harness. Remove the nut and bolt.



20. Drain the transmission fluid 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).

21. Remove 4 bolts.



22. Install the special tool.



23. Install the special tool.



24.

NOTE: Raise the transmission jack.

Remove the right-hand transfer case mount.

• Remove 4 bolts.
• Remove the nut.

25. Together with your partner, remove the transfer case.

• Remove 4 bolts.
• Unscrew 2 nuts.