Installing a 4.0L Transfer Case (Discovery 3)

Installation

1. With the help of an assistant, install the transfer case.

• Clean the contact surfaces of the parts.
• Lubricate the input shaft splines with Weicon TL7391 grease.
• Install the sealing ring.
• Align the fuel line support bracket.
• Using the special tool, tighten the bolts to a tightening torque of 45 Nm.

2. Connect the breather pipe.

3. Position the fuel line support bracket.

• Tighten the bolts to a torque of 10 Nm.
• Secure the fuel lines.
• Place the selector cable into the guide bracket.

4. Connect the electrical connectors.

5. Secure the wire harness to the transfer case.

• Secure with a clamp.
• Tighten the bolts to a torque of 25 Nm.

6. Install the gearbox mount cushion.

• Clean the contact surfaces of the parts.
• Tighten the bolts to a torque of 60 Nm.

7. Install the rear propeller shaft. For more information, refer to Rear Propeller Shaft (47.15.03)

8. Install the front propeller shaft. For more information, refer to Front Propeller Shaft - 4.0L (47.15.02)

9. Connect the ground cable to the battery. For more information, refer to Specification.

10. Using T4, recalibrate the new transfer case.