Defender. Manual — part 183
19. Remove the special tool.
20. Install the insulation pad support bracket.
21. NOTE: Position the differential lock to the left, to reduce
tension on the insulation.
Install the insulation pad.
22. Install the transmission cover panel.
Install the screws.
23. Install the gaiter with the selector levers attached.
Install the selector levers.
Fully seat the gaiter.
24. Install the transmission cover panel floor covering.
25. Install the parking brake lever.
Tighten to 25 Nm (18 lb.ft).
26. Install the parking brake lever gaiter.
Install the clips.
27. Reposition the LH carpet.
28. Install the floor console.
For additional information, refer to:
Floor Console
(501-12
Instrument Panel and Console, Removal and Installation).
Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Transfer Case Extension Housing
In-vehicle Repair
Removal
1. Drain transfer case oil.
For additional information, refer to:
Transfer Case Draining
and Filling
(308-07A Transfer Case - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, General Procedures).
2. Remove transfer case rear output shaft seal.
For additional information, refer to:
Transfer Case Rear
Output Shaft Seal
(308-07A Transfer Case - 2.4L Duratorq-
TDCi HPCR (103kW/140PS) - Puma, In-vehicle Repair).
3. Mark extension housing to main casing for assembly
purposes.
4. Note position of shoulder bolt, remove 6 bolts securing
extension housing to main casing.
Installation
1. Clean extension housing, mating face on main casing and
sealant from bolt threads.
2. Apply sealant, Part No. STC 4600 to mating flange on output
shaft housing.
3. Fit extension housing to main casing ensuring that splines of
output shaft are engaged in differential.
4. Apply sealant, Part No. STC 50552 to bolt threads.
5. Fit bolts and tighten by diagonal selection to 45 Nm (33
lbf.ft).
6. Fit transfer case rear output shaft seal. For additional
information, refer to:
Transfer Case Rear Output Shaft Seal
(308-07A Transfer Case - 2.4L Duratorq-TDCi HPCR
(103kW/140PS) - Puma, In-vehicle Repair).
7. Fill transfer case with oil.
For additional information, refer to:
Transfer Case Draining
and Filling
(308-07A Transfer Case - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, General Procedures).
Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Transfer Case Front Output Shaft Seal
In-vehicle Repair
Special Tool(s)
Output Shaft Flange Holding Tool
205-053
General Purpose Puller
100-005A
Replacer, Oil Seal
307-479
Removal
1.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the vehicle on safety
stands.
Raise and support the vehicle.
2. Drain the transfer case.
For additional information, refer to:
Transfer Case Draining
and Filling
(308-07A Transfer Case - 2.4L Duratorq-TDCi
HPCR (103kW/140PS) - Puma, General Procedures).
3. NOTE: Mark the front driveshaft to transfer case drive
flange.
Release the driveshaft from the transfer case output drive
flange.
Remove and discard the 4 nuts.
4. Using the special tool, restrain the transfer case front
4. Using the special tool, restrain the transfer case front
output flange.
Remove and discard the nut and felt washer.
5. Remove the transfer case front output flange.
If necessary use the special tool to remove the
transfer case front output flange.
6. Using a suitable tool, remove and discard the transfer case
front output shaft seal.
Installation
1. NOTE: Clean the component mating faces.
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