Removal/Installation
REMOVAL1. 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.
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 gearbox brackets.
23. Position adaptor plate to transmission lift. Secure with bolts.
24. Raise transmission lift. Secure adaptor plate to transfer gearbox.
25. Remove 6 bolts securing transfer gearbox.
26. Adjusting tilt as necessary, release transfer box from gearbox, Lower transmission lift.
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 gearbox on lift, Adjust tilt as necessary to align shafts.
32. 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 multiplug 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. Install propeller shaft guard. Tighten bolts.
44. Guide hand brake cable through grommet in transmission tunnel.
45. Install exhaust front pipe.
46. Diesel Vehicles: Install 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. Install seal around gearbox remote housing to transmission tunnel aperture.
52. Position gear lever. Secure with bolts. Tighten to 25 Nm (18 ft. lbs.).
53. Install gaiter and ring. Secure with nuts.
54. Install center console.
55. Automatic Vehicles: Install window switch pack.
56. Reconnect battery negative lead.