Disassembly of Transfer Case

1. Clean exterior of transfer box.
2. Drain and discard the oil, install drain plug.





3. Slacken bolt to release transmission brake adjustment.





4. Remove countersunk screw securing transmission brake drum, remove drum.

NOTE: 2 screws may be installed.

5. Make suitable alignment marks between transmission brake backplate and rear output housing.
6. Remove 4 bolts securing transmission brake backplate, remove backplate.





7. Remove Allen screw securing vehicle speed sensor-if installed.
8. Remove vehicle speed sensor, remove and discard O-ring-if installed.





9. Remove 6 bolts securing bottom cover, remove cover.





10. Release staking from intermediate shaft nut, remove and discard nut.
11. Remove bolt securing anti-rotation plate, remove plate.





12. Using a soft metal drift on threaded end of intermediate shaft, drive shaft out of main casing.
13. Remove and discard O-ring from intermediate shaft.
14. Remove and discard O-ring from main casing.





15. Wrap a suitable length of wire around intermediate gears and using assistance, lift gears out of main casing.





16. Remove and discard 2 taper roller bearings from intermediate gears.
17. Remove and discard collapsible spacer from intermediate gears.

CAUTION: Do not remove bearing tracks at this stage.

NOTE: Discovery cover plate illustrated.





18. Make suitable alignment marks between cover plate/power take-off cover, mainshaft input gear bearing housing and main casing.
19. Noting installed position of stud nut and harness/speedometer cable clip, remove 5 bolts and stud nut securing cover plate/power take-off cover, recover clip.
20. Remove cover plate/power take-off cover.





21. Remove mainshaft input gear bearing housing.

CAUTION: Do not remove mainshaft input gear bearing track at this stage.





22. Remove mainshaft input gear together with taper roller bearings.

NOTE: Input gear installed to Defender transfer boxes has an additional dog tooth gear-see inset on illustration.





23. Remove and discard mainshaft oil seal from main casing.

CAUTION: Do not remove mainshaft input gear bearing track at this stage.





24. Remove 6 bolts securing high/low cross shaft housing.
25. Remove cross shaft housing.

CAUTION: Do not carry out further dismantling of cross shaft housing at this stage.





26. Slacken locknut and remove differential lock warning lamp switch from front output housing.
27. Clean sealant from threads of switch and output housing.





28. Noting installed position of longest bolt, remove 8 bolts securing front output housing to main casing.
29. Remove front output housing.

NOTE: Dowel located.

CAUTION: Do not carry out further dismantling of front output housing at this stage.





30. Noting their installed position, remove shoulder bolt, 5 bolts and 2 washers securing rear output housing to main casing.
31. Remove rear output housing.

NOTE: Dowel located.

CAUTION: Do not carry out further dismantling of rear output housing at this stage.





32. Remove plug securing high/low selector shaft detent spring and ball.
33. Remove detent spring.
34. Remove ball using a stick magnet.

CAUTION: Suitably identify plug, detent spring and ball to their installed positions, do not interchange with differential lock selector shaft detent components.





35. Remove 4 bolts securing interlock solenoid cover, remove cover and Belleville washer.
36. Remove interlock solenoid.
37. Remove neutral warning lamp switch and washer.





38. Withdraw differential assembly together with high/low selector shaft and fork.