Range Rover. Manual — part 148
TRANSFER BOX
9
REPAIR
Refit
27. Manual Vehicles: Renew gearbox output shaft
seal.
See MANUAL GEARBOX, Repair.
28. Automatic Vehicles: Renew gearbox output
shaft seal.
See AUTOMATIC GEARBOX,
Repair.
29. Ensure mating faces are clean.
30. Lubricate input shaft with transmission fluid.
31. Raise transfer box on lift. Adjust tilt as necessary
to align shafts.
32. Engage shafts. Locate transfer box dowels to
gearbox.
33. Secure transfer box to gearbox with bolts.
Tighten to
45 Nm. (33 lbf.ft)
34. Remove transmission lift.
35. Connect multiplugs to High/Low motor and
output shaft speed sensor.
36. Connect Lucars to transfer box fluid temperature
sensor.
37. Secure harness in clips.
38. Raise gearbox on cross beam.
39. Automatic vehicles. Position selector cable
abutment bracket to gearbox. Secure with bolts.
40. Raise one wheel on each axle to allow rotation
of propeller shafts.
41. Position propeller shafts to transfer box flanges.
Align marks.
42. Secure shafts with nuts and bolts. Tighten to
48 Nm. (35 lbf.ft)
43. Fit propeller shaft guard. Tighten bolts.
44. Guide hand brake cable through grommet in
transmission tunnel.
45. Fit exhaust front pipe.
See MANIFOLD AND
EXHAUST SYSTEM, Repair.
46. Diesel Vehicles. Fit chassis cross member.
See CHASSIS AND BODY, Repair.
47. Automatic Vehicles: Adjust gear selector cable.
See AUTOMATIC GEARBOX, Adjustment.
48. Replenish gearbox and transfer box fluids.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
49. Lower lift.
50. Connect handbrake cable to lever, secure with
clevis pin and clip.
Manual Vehicles:
51. Fit seal around gearbox remote housing to
transmission tunnel aperture.
52. Position gear lever. Secure with bolts. Tighten
to
25 Nm. (18 lbf.ft)
53. Fit gaiter and ring. Secure with nuts.
54. Fit centre console.
See CHASSIS AND BODY,
Repair.
55. Automatic Vehicles:Fit window switch pack.
See ELECTRICAL, Repair.
56. Reconnect battery negative lead.
41
TRANSFER BOX
NEW RANGE ROVER
10
REPAIR
TRANSFER BOX - FROM 99MY
Service repair no - 41.20.25.
Remove
1. Position vehicle on a four post lift.
2. Release fixings and remove battery cover.
3. Disconnect battery earth lead.
4. Release clips securing cooling fan cowl and
remove cowl.
5. Automatic models: Remove window switch
pack.
See ELECTRICAL, Repair.
6. Manual models: Remove centre console.
See
CHASSIS AND BODY, Repair.
7. Manual models: Remove 6 nuts securing gaiter
ring and remove gaiter ring and gaiter. Remove
2 bolts securing gear lever and remove lever.
8. With the handbrake released, remove clip and
clevis pin securing handbrake cable to
handbrake.
9. Raise vehicle and release handbrake cable and
grommet from tunnel.
10. Drain gearbox fluid.
See AUTOMATIC
GEARBOX, Repair.
11. Drain transfer box oil.
See SECTION 10,
Maintenance. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information.
12. Petrol models: Remove exhaust front pipe.
See
MANIFOLD AND EXHAUST SYSTEM, Repair.
13. Diesel models: Remove chassis crossmember.
See CHASSIS AND BODY, Repair.
TRANSFER BOX
11
REPAIR
14. Remove 4 bolts securing transmission mounting
assembly and remove assembly.
15. Support engine and gearbox with transmission
jack.
16. Remove 4 bolts securing rear propeller shaft
guard and remove guard.
17. Mark transfer box and propeller shaft flanges to
aid re-assembly.
18. Raise one wheel on each axle to allow rotation
of propeller shafts.
19. Remove 4 nuts from each propeller shaft flange.
20. Release propeller shafts and tie aside.
21. Lower transmission for access.
22. Automatic models: Remove split pin securing
gear selector cable trunnion to gearbox lever
and release trunnion.
41
TRANSFER BOX
NEW RANGE ROVER
12
REPAIR
23. Remove 2 bolts securing gear selector cable
abutment bracket and harness support bracket
to gearbox, and position selector cable and
brackets aside.
24. Remove banjo bolt securing breather pipe to
transfer box, remove and discard sealing
washer.
CAUTION: Plug the connections.
25. Disconnect 2 Lucars from transfer box oil
temperature sensor.
26. Disconnect multiplugs from High/Low motor and
output shaft speed sensor.
27. Release harness from 2 clips.
28. Remove bolt securing fuel pipe and purge pipe
retaining bracket to transfer box and release
bracket.
29. Position adaptor plate LRT-99-012 to
transmission lift and secure with nuts and bolts.
30. Raise and adjust transmission lift so that
LRT-99-012 is correctly located to transfer box.
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