Transfer case: models with K1.8 engine (Freelander 1)

Dismantling

1. Disconnect the negative battery terminal.

2. Remove the rear cross member.

FRONT SUSPENSION, REPAIR WORK, Front subframe.

3. Remove the exhaust pipe.

COLLECTORS AND EXHAUST SYSTEM: MOD. K, volume 1.8, REPAIR WORK, Intake pipe.

4. Drain the oil from the transfer case.

TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for North American market countries.

5. Drain the oil from the gearbox.

MECHANICAL GEARBOX - PG1, ADJUSTMENTS, Replacing transmission oil in the box.

6. Unscrew the 3 bolts securing the right mudguard panel and remove the panel.



7. Install the LRT-54-026 tool onto the inner joint of the drive shaft. Using a lever, release the drive shaft from the transfer case.



8. With the help of a partner, move the hub outward and remove the drive shaft from the transfer case.

CAUTION: When removing the drive shaft, be careful not to damage the oil seal.

9. Remove and discard the drive shaft retaining ring.



10. To facilitate subsequent assembly, apply position marks to the front propeller shaft.

11. Raise one rear wheel so that you can rotate the driveshaft to gain access to the bolts.

12. Unscrew 6 nuts and remove the bolts securing the propeller shaft to the drive flange of the transfer case.

13. Remove the propeller shaft from the transfer case drive flange and tie it to the side.

CAUTION: When removing the three-roller joint from the transfer case, care must be taken. To avoid damaging the boot, it must not be completely stretched, and the joint housing must be protected from impacts.

14. Unscrew the 3 nuts securing the damper to the rear axle drive shaft housing.

15. Remove the damper.

16. Disconnect the breather hose from the transfer case housing.

17. Install a container to collect the leaking coolant.

18. Loosen the clamp and disconnect the cooling system hoses from the transfer case.



19. Unscrew the bolt securing the lower cross member to the bracket on the pallet.

20. Remove the lower engine mount cross member.



21. Unscrew the 3 bolts securing the lower cross member bracket to the pan and remove the bracket.





22. Unscrew the upper bolt securing the transfer case bracket to the cylinder block.

23. Remove the 5 bolts securing the bracket to the transfer case.

24. Unscrew the 3 bolts securing the transfer case bracket to the pan and remove the bracket.



25. Unscrew the 4 bolts securing the transfer case.

26. With the help of a partner, separate the transfer case from the gearbox and remove the transfer case.



27. Remove the O-ring from the transfer case and discard it.

Installation

1. Clean the mating surfaces of the transfer case and gearbox.

2. Lubricate the new O-ring and install it in place.

3. With the help of a partner, install the transfer case.

4. Screw in the bolts securing the transfer case to the gearbox and pull their mating surfaces together without tightening the bolts completely.

5. Install the transfer case bracket and tighten the mating surfaces together.

6. Finally tighten the bolts securing the transfer case to the gearbox. Tightening torque 90 Nm.

7. Finally tighten the transfer case bracket bolts in the following sequence:

• Five bolts for fastening the bracket to the transfer case with a torque of 50 Nm
• One bolt for fastening the bracket to the cylinder block with a torque of 45 Nm
• Three bolts for fastening the bracket to the pan with a torque of 88 Nm.

8. Install the lower cross member bracket onto the tray, screw in the bolts and tighten them to a torque of 100 Nm.

9. Install the lower engine crossmember, screw in the crossmember mounting bolt to the gearbox bracket, but do not tighten it.

10. Connect the cooling system hoses and secure them with clamps.

11. Connect the breather hose to the transfer case.

12. Install the damper on the rear axle drive shaft housing, tighten the nuts and tighten them to a torque of 25 Nm.

13. Clean the propeller shaft flange and the mating flange.

14. Install the cardan shaft on the drive flange of the transfer case so that the previously applied marks are aligned. Tighten the nuts and bolts to a torque of 40 Nm.



15. Check the condition of the drive shaft seal and replace it if it is damaged or worn.

16. Clean the drive shaft and splines.

17. Install a new snap ring onto the end of the drive shaft.

18. With the help of a partner, move the hub outward and insert the drive shaft into the transfer case, being careful not to damage the seal.

CAUTION: Press down on the drive shaft to ensure that the snap ring is seated in its groove and holds the shaft.

19. Install the mudguard panel and secure it with bolts.

20. Install the exhaust pipe.

COLLECTORS AND EXHAUST SYSTEM: MOD. K, volume 1.8, REPAIR WORK, Intake pipe.

21. Install the rear beam in place.

FRONT SUSPENSION, REPAIR WORK, Front subframe.

22. Finally tighten the bolt securing the lower cross member to the pan bracket to a torque of 80 Nm.

23. Fill the transfer case with oil to the required level.

TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for North American market countries.

24. Fill the gearbox with oil.

MECHANICAL GEARBOX - PG1, ADJUSTMENTS, Replacing transmission oil in the box.

25. Connect the negative battery terminal.

26. Fill the engine with coolant.

COOLING SYSTEM: MODIFICATION K, volume 1.8, ADJUSTMENTS, Filling the cooling system.