Removing and installing transfer case TD6 (Range Rover 3)

Before disconnecting the battery, make sure that all the requirements and conditions contained in the section on disconnecting the battery are met.

GENERAL INFORMATION, Precautions when working with electrical equipment.

Dismantling

1. Put the car on a lift.

2. Disconnect the negative plug from the storage battery.

3. Remove the cover that covers the engine in the engine compartment.

ENGINE TD6, REPAIR WORK, Upper engine cover.

4. Remove the viscous coupling with the fan.

COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.

5. Put the car on a lift.

6. Drain the fluid from the transfer case.

TRANSFER BOX, ADJUSTMENTS, Fluid drain and fill.

7. Remove the rear driveshaft.

DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - rear.

8. Remove the front propeller shaft.

DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.

9. Turn away 5 nuts and remove the right thermal screen.

10. Install and drive a jack under the transfer case housing.

11. Remove the bolt and nut connecting the transmission support assembly to the cross frame.

12. Turn out 6 screws of fastening of a cross frame and remove a cross frame.

13. Remove the silent block from the support.

14. Lower a transmission on a jack.

WARNING: Do not let the transmission hang on the selector cable.

15. Remove the block from the connector of the transfer case shift drive assembly.

16. Remove the transfer case crankcase ventilation hose.

CAUTION: Always plug fittings and openings to keep dirt out of the system.

17. Support the transfer case on a jack.

18. Turn out 9 screws like Torx and remove a distributing box.

NOTE: Do not further disassemble if the assembly is being removed for ease of access only.

19. Turn out 3 Torx screws of fastening of an oscillation damper and remove an oscillation damper.

20. Lubricate the LRT-41-018/4 center screw with molybdenum grease and assemble the transfer box support remover as shown.

CAUTION: Make sure the tool alignment indicator is in the lowest position. The alignment indicator is a flat groove on the LRT-41-018/1 and LRT-41-018/2 fixtures.

Assembly

1. Clean the support and mating surfaces.

2. Lubricate the new support and drill in the transfer case housing to facilitate assembly.

3. Position the new support at the rear of the transfer case and start the connection. The support must move without distortion, and the mounting marks must match each other.

NOTE: Move the alignment mark to the side of the support for easier alignment.

4. Lubricate the center screw of tool LRT-41-018/4 with molybdenum grease to install the transfer case support. Start with the center screw fully out, and when the support is about 75 percent in, reduce the length of the center screw by screwing it all the way into the LRT-41-018/1 slab. In this case, the central screw of the LRT-41-018/4 device will not come into contact with the transmission fluid and contaminate it.

CAUTION: Make sure the alignment indicator is in the lowest position.

5. Make sure that the support is installed without distortion. If necessary, restore parallelism by hitting the base plate with a wooden mallet.

6. Clean vibration damper and mating surfaces.

7. Install the vibration damper and tighten the Torx screws to 23 Nm.

8. Clean the transfer case mating surface, dowel pins, and pin holes.

9. Clean the input shaft and mating surface.

10. Apply a light coat of anti-seize lubricant to the shaft splines.

11. Install the transfer case and tighten the Torx screws to 43 Nm.

12. Attach the ventilation hose to the transfer case.

13. Attach the cable block.

14. Remove the jack from under the transfer case.

15. Install silent blocks.

16. Connect the cross frame to the support, install the bolt with the nut, but do not fully tighten it.

17. Jack up the gearbox.

18. Establish a cross frame, wrap screws of fastening and tighten them with the moment of 68 Нм.

19. Remove the jack from under the gearbox.

20. Tighten the nut and bolt securing the support to the transverse frame with a torque of 100 Nm.

21. Install the heat shield and tighten its nuts.

22. Install the rear driveshaft.