Transfer Case Front Output Shaft Seal 4.4L (Discovery 3)

Special tool

Mounting device (LRT-41-019) 307-486

Mounting device 308-636

Mounting device 205-818

Removal

1. Disconnect the ground cable from the battery. For more information, refer to Specification.

2.

CAUTION: Never work on a vehicle supported solely by a jack. Always support the vehicle securely.

Raise and support the vehicle.

3. Drain the liquid from the transfer case. For more information, refer to Draining transmission fluid from the transfer Case and pouring transmission Fluid into the transfer Case (41.20.04)

4. Remove the transfer case. For more information, refer to Transfer Case - 4.4L (41.20.25.99)

5. With the help of an assistant, secure the transfer case to a flat surface with the contact surface facing down. gears. Secure it with 2 bolts.

6.

CAUTION: Always use eye protection.

Remove the shift motor.

• Remove 4 bolts.
• Remove any foreign matter from the bolt holes.

7.

CAUTION: Always use eye protection.

Remove the 17 Torx bolts securing the transfer case housing.

• The 2 bolts shown in the figure must remain fully tightened.
• Remove any foreign matter from the bolt holes.

8. With the help of an assistant, disconnect the transfer case and secure it to a flat surface with the rear surface of the case facing down.

9.

CAUTION: Always use eye protection.

CAUTION: Be careful not to damage mating surfaces.

Remove the front half of the transfer case.

• Remove the 2 remaining Torx bolts
• Remove any foreign matter from the bolt holes.
• Use a soft-headed hammer.

10.

CAUTION: Mark the installation positions of the special washers.

Remove 2 special washers.



11. Remove the primary shaft and oil pump assembly. Remove the working fluid pump intake pipe.





12. Remove the front outlet flange.

• Compress the retaining ring.
• Press the flange through the bearing.
• Remove and discard the retaining ring.

13.

CAUTION: Be careful not to damage the sliding surface and the seal guide surface.

Remove the outlet flange seal.



14. Remove the output flange bearing.

Installation

1. Remove the sealant from the transfer case mating surfaces.

2. Clean the magnetic filter.

3.

CAUTION: The rounding on the inner ring of the bearing must face the seal.

Using a special tool, install the output flange bearing. Clean the mating surfaces of the parts.



4. Using a special tool, install a new oil seal.

• Clean the contact surfaces of the parts.
• Lubricate the new seal.

5.

CAUTION: Before installing the output flange, center the retaining ring in the retaining ring groove.

CAUTION: Be very careful that the retaining ring enters the bearing at a right angle.

With the help of an assistant, using a special tool, install the drive flange.

• Clean the contact surfaces of the parts.
• Install a new snap ring.
• Make sure the retaining ring is fully engaged and secures the drive flange.

6.

CAUTION: Make sure the washers are installed correctly.

Install 2 special washers. Clean the parts.

7.

CAUTION: Make sure the oil pump is installed on the centering pin.

Install the input shaft and oil pump assembly.

• Clean the parts.
• Secure the suction tube of the working fluid pump.

8. Apply a 2mm wide bead of sealant to one of the transfer case mating surfaces as shown in the figure.

• Clean the contact surfaces of the parts.
• Clean the pins and pin holes.

9. Install the front half of the transfer case. Tighten the 2 Torx bolts evenly to 35 Nm.



10. With the help of an assistant, disconnect the transfer case and secure it to a flat surface with the surface that contacts the gearbox facing down.



11. Tighten the remaining Torx bolts to 35 Nm.

12. Install the shift motor.

• Clean the parts.
• Tighten the Torx bolts to 25 Nm.

13. With the help of an assistant, disconnect the transfer case. Remove the 2 bolts.

14. Install the transfer case. For more information, refer to Transfer Case - 4.4L (41.20.25.99)

15. Fill the transfer case with the recommended liquid. For more information, refer to Draining transmission fluid from the transfer Case and pouring transmission Fluid into the transfer Case (41.20.04)

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