Transfer Box, Removing And Installing
Transfer Box - V8
Service repair No - 41.20.25.99
Remove
1. Remove front exhaust pipe.
2. Drain transfer box oil.
3. Remove 8 bolts securing rear cross member and remove cross member.
4. Remove 3 nuts securing intermediate silencer to tail pipe.
5. Release silencer from mounting rubbers, remove silencer and discard gasket.
6. Remove front propeller shaft.
7. Remove rear propeller shaft.
8. Remove handbrake drum retaining screw and remove handbrake drum.
9. Remove 4 bolts from handbrake back plate, release back plate and tie aside.
10. Remove clevis pin and 'C' washer securing high/low ratio selector cable to selector lever and release cable from abutment bracket.
11. Remove 2 cable ties securing cable to fuel pipes.
12. Disconnect 2 Lucars from oil temperature sensor and disconnect reverse lamp switch multiplug.
13. Remove banjo bolt securing breather pipe and discard washers.
14. If fitted - Disconnect 2 Lucars from differential lock switch.
15. Release and disconnect transfer box neutral switch multiplug.
16. Remove 4 bolts from transfer box bottom plate, position support plate LRT-99-010 to transfer box and tighten bolts.
17. Position gearbox support jack and secure support plate to jack using 4 bolts.
18. Remove 3 bolts securing transfer box to gearbox.
19. Fit 3 guide studs LRT-41-009 through transfer box bolt holes to support it during removal.
20. Remove 2 bolts and nut securing transfer box to gearbox case. If securing stud is removed during this operation, it must be discarded and a new stud fitted.
21. Position a jack to support gearbox and engine.
22. Remove 4 bolts and nut securing RH mounting to body and transfer box.
23. Remove nut securing LH mounting to body.
24. Raise gearbox and remove RH mounting.
25. With assistance, remove transfer box from gearbox.
26. Remove input shaft oil seal.
Refit
1. Fit new input shaft oil seal.
2. Clean transfer box to gearbox mating faces.
3. Raise transfer box on jack and align to guide studs LRT-41-009.
4. Clean transfer box to gearbox bolt threads.
5. Apply Loctite 290 to bolt and stud threads.
6. Fit and lightly tighten 2 bolts and nut securing transfer box to gearbox. If new stud is to be fitted apply Loctite 290 to threads of stud and tighten to 45 Nm (33 lbf.ft)
7. Remove guide studs, fit and lightly tighten 3 bolts.
8. Tighten bolts and nut by diagonal selection to 45 Nm (33 lbf.ft).
9. Position gearbox RH mounting and tighten bolts to 85 Nm (63 lbf.ft).
10. Tighten gearbox RH mounting nut to 48 Nm (35 lbf.ft).
11. Fit nut to LH mounting and tighten to 8 Nm (35 lbf.ft).
12. Remove 4 bolts securing support plate to gearbox jack.
13. Remove 4 bolts securing support plate LRT-99-010 to transfer box and remove plate.
14. Clean threads of bottom plate bolts.
15. Apply Loctite 290 to threads of bolts.
16. Fit 4 bolts securing bottom plate and tighten to 25 Nm (18 lbf.ft).
17. Using new washers position breather pipe and tighten banjo bolt.
18. Connect multiplug to transfer box neutral switch and secure harness.
19. If fitted - Connect Lucars to differential lock switch.
20. Connect multiplug and Lucars to reverse lamp switch and oil temperature sensor.
21. Position high/low ratio selector cable and secure with 'C' washer and clevis pin.
22. Secure cable to fuel pipes with new cable ties.
23. Clean handbrake back plate and mating face.
24. Position handbrake back plate, fit bolts and tighten to 75 Nm (55 lbf.ft).
25. Clean handbrake drum.
26. Fit handbrake drum and lighten retaining screw.
27. Fit front propeller shaft.
28. Fit rear propeller shaft.
29. Clean exhaust silencer and tail pipe mating faces.
30. Position silencer and secure on mountings, using a new gasket align to tail pipe, fit nuts and tighten to 25 Nm (18 lbf.ft).
31. Position rear cross member, fit bolts and tighten to 26 Nm (19 lbf.ft).
32. Refill transfer box with oil.
33. Fit front exhaust pipe.