4.4L transfer case rear output shaft seal (Discovery 3)

Special tool

Device for removal/installation (LRT-54-015) 205-726

Installation tool for seals 308-637

Installation tool 204-525/1

Removing

1. Disconnect a wire of weight from the storage battery. For more information refer to Specification.

2.

WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Always place secure supports under the vehicle.

Raise and support the vehicle.

3. Drain the fluid from the transfer case. For more information, refer to Draining Transmission Fluid from the Transfer Case and Filling 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 a second person, secure the transfer case to a flat surface with the contact surface of the transmission facing down. Secure it with 2 screws.

6.

WARNING: Be sure to use eye protection.

Remove the shift motor.

• Turn out 4 bolts.
• Remove debris from bolt holes.

7.

WARNING: Be sure to 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 debris from bolt holes.

8.

WARNING: Be sure to use eye protection.

CAUTION: Be careful not to damage mating surfaces.

Remove the rear half of the transfer case.

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

9. Remove the differential block. Remove the spacer.



10.

NOTE: Remove complete parts.

Remove clutch, chain and sprocket.



11. Remove the rear outlet flange.

• Squeeze the retaining ring.
• Push the flange through the bearing.
• Remove and discard retaining ring.

12.

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

Remove the outlet flange seal.



13. Remove the output flange bearing. Remove the snap ring.




14. Separate the front half of the transfer case from a flat surface. Turn out 2 bolts.

Installation

1. Remove the sealant from the contact surfaces of the transfer case.

2. Clean the magnetic filter.

3.

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

Using the special tool, install the output flange bearing.

• Clean the mating surfaces of the parts.
• Install retaining ring.

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

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

5.

CAUTION: Before installing the outlet flange, center the circlip in the circlip groove.

ATTENTION: Be very careful, the retaining ring must enter the bearing at a right angle.

Together with the assistant, using a special tool, install the drive flange.

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

6. Secure the rear half of the transfer case with the back side facing down on a flat surface.

7.

NOTE: Rotate the differential to engage the splines.

Install the differential block.

• Clear the details.
• Install the spacer.

8.

NOTE: Rotate the assembly to engage the clutch discs.

NOTE: To open the levers of the actuator, use forceps to remove and install the locking rings.

Install the clutch.

• Clear the details.
• Engage the levers of the actuator.

9.

WARNING: The dark chain links must be facing up as shown in the picture.

NOTE: The splined inner hole of the sprocket must face up as shown.

Install chain and sprocket. Clear the details.



10. Apply a 2mm bead of sealant to one of the transfer case contact surfaces as shown.

• Clean the contact surfaces of the parts.
• Clean pins and pin holes.
• Apply a 2 mm bead of sealant to one of the contact surfaces of the transfer case as shown in the illustration.

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



12. Tighten the remaining Torx bolts to 35 Nm.

13. Install the shift motor.

• Clear the details.
• Tighten the Torx bolts with a tightening torque of 25 Nm.

14. Together with an assistant, remove the transfer case from a flat surface. Turn out 2 bolts.

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

16. Fill the transfer case with the recommended fluid. For more information, refer to Draining Transmission Fluid from the Transfer Case and Filling Transmission Fluid into the Transfer Case (41.20.04)

17. Connect a wire of weight to the storage battery. For more information refer to Specification.