Installing a 4.4L Transfer Case (Discovery 3)

Installation

1. Install the transfer case with assistance.

• 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.
• Tighten the bolts using a special tool. (tightening torque 45 Nm).

2. Connect the breather hose.

3. Reinstall the fuel line support bracket.

• Tighten the bolts (tightening torque 10 Nm).
• Connect the fuel lines.
• Install the selector cable into the guide.

4. Connect the electrical connectors.

5. Connect the wire harness to the transfer case.

• Secure with a clamp.
• Tighten the bolts (tightening torque 25 Nm).

6. Install the transmission support cushion.

• Tighten the bolts (tightening torque 25 Nm).
• Tighten the bolts (tightening torque 60 Nm).

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

8. Install the front drive shaft. For more information, refer to Front Drive Shaft - 4.4L (47.15.02)

9. Install the exhaust system. For more information, refer to Exhaust System (10/30/08)

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

11. Using T4, recalibrate the new transfer case.