Removal/Installation

Remove

1. Position vehicle on four post lift.
2. Disconnect battery negative lead.
3. Automatic Vehicles. Remove window switch pack.


Manual Vehicles:

4. Remove center console.





5. Remove 6 nuts securing gaiter ring. Remove ring and gaiter.





6. Remove 2 bolts securing gear lever. Remove lever.


All Vehicles:

7. Release handbrake.





8. Remove handbrake cable clevis pin.
9. Raise lift. Drain gearbox and transfer box oil.
10. Support transmission with cross beam.
11. Remove exhaust front pipe.
12. Diesel Vehicles. Remove chassis cross member.
13. Release hand brake cable from grommet in tunnel.





14. Remove 4 bolts securing rear propeller shaft guard. Remove guard
15. Mark flanges on propeller shafts and transfer box to aid reassembly.
16. Raise one wheel on each axle to allow rotation of propeller shafts.
17. Remove fixings securing shafts to transfer box. Release shafts. Tie aside.





18. Automatic Vehicles. Disconnect gear selector cable trunnion from gearbox lever. Remove 2 bolts securing selector cable abutment bracket to gearbox. Place selector cable aside.
19. Lower gearbox for access.





20. Disconnect 2 Lucars from transfer box fluid temperature sensor.
21. Disconnect multiplugs from High/Low motor and output shaft speed sensor.
22. Release harness from 2 clips on transfer box brackets.
23. Position adapter plate LRT-99-012 to transmission lift. Secure with bolts.
24. Raise transmission lift. Secure adapter plate to transfer gearbox.
25. Remove 6 bolts securing transfer box.
26. Adjusting tilt as necessary, release transfer box from gearbox. Lower transmission lift.

Refit
27. Manual Vehicles: Renew gearbox output shaft seal.
28. Automatic Vehicles: Renew gearbox output shaft seal.
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. Engage shafts. Locate transfer box dowels to gearbox.
33. Secure transfer box to gearbox with bolts. Tighten to 45 Nm (33 ft. lbs.)
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 ft. lbs.)
43. Fit propeller shaft guard. Tighten bolts.
44. Guide hand brake cable through grommet in transmission tunnel.
45. Fit exhaust front pipe.
46. Diesel Vehicles. Fit chassis cross member.
47. Automatic Vehicles: Adjust gear selector cable.
48. Replenish gearbox and transfer box fluids.
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 ft. lbs.).
53. Fit gaiter and ring. Secure with nuts.
54. Fit center console.
55. Automatic Vehicles: Fit window switch pack.
56. Reconnect battery negative lead.