Transfer case front output shaft seal (Defender 2007+)

Special tool(s)

	Secondary shaft flange locking device 205-053
	Universal puller 100-005A
	Removable Device, Oil Seal 307-479

Removal

1.

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

Raise and support the vehicle.

2. 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).

3.

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

Disconnect the propeller shaft from the output drive flange on the transfer case. Loosen and discard the 4 nuts.



4. Using the special tool, restrict the front output flange of the transfer case. Unscrew and discard the nut and felt gasket.





5. Remove the front output flange of the transfer case. If necessary, use a special tool to remove the front output flange of the transfer case.



6. Using the appropriate tool, remove and discard the transfer case secondary shaft front seal.

Installation

1.

NOTE: Clean the contact surfaces of the elements.

NOTE: Use the end of the tool marked "FRONT" to install the seal (front end).

Using the special tool, install a new transfer case secondary shaft front seal.



2.

NOTE: Install a new felt gasket.

Install the transfer case front output flange.

• Install the bushing.
• Screw on a new nut and tighten (tightening torque 162 Nm).

3.

NOTE: Install new nuts.

The article is based on information from the website www.lrman.ru

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



4. 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).