Defender. Manual — part 179
Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Transfer CaseVehicles With: 6-Speed Manual Transmission - MT82
Description and Operation
COMPONENT LOCATION
Item
Part Number
Description
1
-
Rear output housing
2
-
Main casing
3
-
Transfer box selector lever
4
-
Breather pipe
5
-
Front output housing
6
-
Selector housing
TRANSFER CASE CROSS SECTION
Item
Part Number
Description
1
-
Main casing
2
-
Front output housing
3
-
Rear output housing
4
-
Dog clutch
5
-
Transmission brake
6
-
Mainshaft input gear
7
-
Selective shim - input gear bearing pre-load
8
-
Intermediate gear cluster
9
-
Intermediate shaft
10
-
Spacer
11
-
Differential assembly
12
-
Selective shim - differential bearing pre-load
13
-
Low range gear
14
-
High/low selector sleeve and hub
15
-
High range gear and bush
16
-
Differential rear bearing
17
-
Front output shaft
18
-
Differential lock selector shaft
19
-
Selector fork
20
-
Rear output shaft
OVERVIEW
The transfer box is a permanent 4-wheel drive, 2-speed ratio reducing transmission, incorporating high and low range
outputs with mechanically lockable centre differential (diff-lock). High range has a ratio of 1.211:1 and low range
3.269:1.
High/low range and diff-lock selection are made via a single lever located next to the main gear lever.
The unit is mounted at the rear of the main transmission and transmits drive to the front and rear drive axle
differentials via the drive shafts.
Integral with the output shafts is a differential assembly, which compensates for speed differences between the front
and rear drive shafts. To improve traction and prevent all the power being transmitted to the drive axle differential
offering the least traction, a diff-lock is provided. The diff-lock should only be engaged during severe off-road conditions
where traction is poor and should be disengaged as soon as conditions permit, for example, when good traction is
available. Selection of differential lock engages, through mechanical linkage, a dog clutch with the front output shaft,
this action locks the centre differential and provides a fixed drive, giving equal power to the front and rear drive shafts.
The transfer box comprises 3 main assemblies:
The main casing
The front output housing
The rear output housing
All housings and cover plates are sealed to the main casing by sealant. Output flange rotary seals are protected against
mud and water ingress by mud shield flingers.
THE MAIN CASING
Item
Part Number
Description
1
-
Main casing
2
-
Retaining plate
3
-
Bolt - retaining plate
4
-
Stake nut - intermediate shaft
5
-
Bearings and outer tracks - mainshaft input gear
6
-
Mainshaft input gear
7
-
Selective shim
8
-
Mainshaft input gear bearing housing
9
-
Cover plate/power take-off cover
10
-
Bolt - cover plate
11
-
Oil temperature switch (if fitted)
12
-
Bearings and outer tracks - intermediate gears
13
-
Collapsible spacer
14
-
Intermediate gears
15
-
Bottom cover plate
16
-
Bolt - bottom cover plate
17
-
O-rings - intermediate shaft
18
-
Intermediate shaft
19
-
Mainshaft oil seal
20
-
Locating dowel
21
-
Detent plug - high/low selector
22
-
Detent spring - high/low selector
23
-
Detent ball - high/low selector
The main casing carries:
the mainshaft input gear
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