Removal and Replacement
41.20.25.99 Transfer gearbox - V8Remove
1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Use LRT-12-214 and LRT-12-215 to loosen viscous coupling lock nut and remove fan assembly from coolant pump.
NOTE: Thread is left handed.
4. Raise vehicle on lift.
5. Drain transfer gearbox oil.
6. Remove rear propeller shaft.
7. Remove front propeller shaft.
8. Remove 5 nuts, release and remove RH heat shield.
9. Support gearbox on a jack.
10. Remove nut and bolt securing mounting to cross member.
11. Remove 6 bolts securing cross member and remove cross member.
12. Remove snubbers from mounting.
13. Lower gearbox on jack.
CAUTION: Do not allow gearbox to hang on gear selector cable.
14. Disconnect multiplug from high/low shift motor.
15. Disconnect breather hose from gearbox.
CAUTION: Always fit plugs to open connections to prevent contamination.
16. Release clips securing oxygen sensor leads to transfer gearbox.
17. Support transfer gearbox on jack.
18. Remove 9 Torx bolts and remove transfer gearbox.
NOTE: Do not carry out further dismantling if component is removed for access only.
19. Remove 4 bolts securing oxygen sensor multiplug retaining brackets from transfer gearbox.
20. Lubricate centre screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown to remove mounting from transfer gearbox.
CAUTION: Ensure tool alignment indicator is at the 6 o'clock position. The tool alignment indicator is a machined flat on LRT-41-018/1 and LRT-41-018/2.
Refit
1. Clean mounting and mating faces.
2. Lubricate new mounting and bore in transfer gearbox casing to aid assembly.
3. Position new mounting to rear face of transfer gearbox, and start entry. Mounting to be parallel, with timing marks aligned.
NOTE: Transfer timing mark to side of mounting to assist with alignment.
4. Lubricate centre screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown, to fit mounting to transfer gearbox. Start with the centre screw at full length and when the mounting is approximately 75 percent fitted, reduce the length of the centre screw by screwing it fully into the base plate LRT-41-018/1. This will ensure the centre screw LRT-41-018/4, does not foul on the gearbox fluid pan.
CAUTION: Ensure tool alignment indicator is at the 6 o'clock position.
5. Ensure the mounting is fitted parallel. If necessary, use a mallet and tap the base plate to maintain a parallel fit.
6. Fit multiplug brackets, tighten bolts to 25 Nm (18 ft. lbs.)
7. Clean transfer gearbox and mating face dowels and dowel holes.
8. Clean input shaft and mating face.
9. Apply thin coat of anti-seize grease to shaft splines.
10. Fit transfer gearbox and tighten Torx bolts to 43 Nm (32 ft. lbs.).
11. Connect multiplug.
12. Connect breather hose to gearbox.
13. Fit and secure oxygen sensor leads.
14. Remove support from transfer gearbox.
15. Fit snubbers.
16. Fit cross member to mounting, fit nut and bolt but do not tighten at this stage.
17. Raise gearbox on jack.
18. Align cross member, fit bolts and tighten to 68 Nm (50 ft. lbs.).
19. Remove support from gearbox.
20. Tighten nut and bolt securing mounting to cross member to 100 Nm (74 ft. lbs.).
21. Fit heat shield and secure with nuts.
22. Fit rear propeller shaft.
23. Fit front propeller shaft.
24. Refill transfer gearbox with oil.
25. Fit fan to pulley and tighten viscous coupling nut to 45 Nm (33 ft. lbs.).