Transfer case rear output shaft seal (Defender 2007+)

Removal

1. Loosen the brake shoe adjusting bolt.



2. Remove the rear propeller shaft.

For more information, refer to the chapter: Rear Propeller Shaft (205-01 Cardan shaft, Removal and installation).

3. Remove the brake drum mounting screw.

4. Remove the brake drum.

5. Secure the transfer case drive flange using LRT-51-003, loosen and discard the drive flange nut, remove and discard the steel and felt washers.



6. Using LRT-99-500 if necessary, remove the drive flange from the transfer case.



7. Remove the secondary shaft rear oil seal from the transfer case and discard it.

Installation

1. Clean the drive flange splines, bearing mating surfaces and gaskets to remove oil and debris. Use Loctite 7063 Degreaser Cleaner.

2. Clean the seal recess, output shaft splines, threads and mating surfaces to remove oil and debris. Use Loctite 7063 Degreaser Cleaner.

3.

CAUTION: The seal must be installed dry.

NOTE: Use the end of the tool marked 'REAR' to install the seal.

Install new seal using LRT-41-012.



4.

CAUTION: Remove Loctite 648 from bearing when installing drive flange. Failure to do so may result in vehicle damage.

Holding the drive flange by the protruding end, apply Loctite 648 to the splines as shown.

• 1. Apply a continuous strip along the splines.
• 2. Apply a second continuous bead 5mm from the end of the flange.

The original text can be found at: LRman.ru





5.

NOTE: It is not necessary to install a new felt filter.

NOTE: Remove excess Loctite 648 from drive flange before installing steel washer.

Install the drive flange onto the output shaft, making sure the drive flange is fully seated. Install a new steel washer

6.

CAUTION: Do not use power or air tools to tighten the drive flange nut.

Install LRT-51-003, screw on new drive flange nut and tighten to 165 Nm (122 lbf/ft).



7. Install the brake drum and tighten the screw.

8. Tighten the adjuster bolt to 25 Nm, then back it out 1/2 turn.

9. Make sure the brake drum can rotate freely.

10. Install the driveshaft.

For more information, refer to the chapter: Rear Propeller Shaft (205-01 Cardan shaft, Removal and installation).



11. Add oil to 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).