Removal And Installation: Removal

NOTE:

Some variation in the illustrations may occur, but the essential information is always correct.
Some components shown removed for clarity.

Disconnect the battery ground cable.
Refer to: SPECIFICATIONS
WARNING: Make sure to support the vehicle with axle stands.

Raise and support the vehicle.
Remove the transfer case.
Refer to: TRANSFER CASE - V6 S/C 3.0L PETROL/V8 N/A 5.0L PETROL/V8 S/C 5.0L PETROL

Refer to: TRANSFER CASE - TDV6 3.0L DIESEL - GEN 2/TDV6 3.0L DIESEL/TDV6 3.0L DIESEL - GEN 1.5
With assistance, secure the transfer case with its transmission mating face down on a flat surface.
If equipped, remove the heat shield.
If equipped, remove the heat shield.
Remove the damper.
CAUTION: Make sure the bolt holes are clean and free of swarf.

Remove the motor.
Remove the sensor.
CAUTION: Make sure the bolt holes are clean and free of swarf.

Remove the 19 transfer box case bolts.
CAUTION: Care must be taken when turning the transfer case over. The transfer case halves must not be allowed to separate.

With assistance, release the transfer case and secure with the rear face of the transfer case facing down on a flat surface.
CAUTION: Care must be taken to avoid damage to the mating surfaces.

Using a soft faced mallet, release the front casing.
Remove the sealant from the transfer case mating faces.
Using the special tool, support the output shaft flange.

Special Tool(s): JLR-308-926
Remove and discard the circlip.
CAUTION: Do not use excessive force while removing the flange assembly.

Remove the front output shaft and flange assembly.
Using a suitable tool, remove and discard the oil seal.
Remove the bearing.