Transfer Case Rear Output Shaft Bearing (G2375897): Installation

The following step(s) applies to: 

All vehicles

1. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Position the special tool as shown, to support the transfer case during the next step.

   Special Tool(s): JLR-308-927 

2. CAUTION: The chamfer on the bearing inner track must face the seal.

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Use the special tool to install the new bearing.

   Special Tool(s): 205-726 

3. Remove the special tool.

   Special Tool(s): JLR-308-927 

4. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   • Use the special tool to install a new seal.

     Special Tool(s): 308-637 

     Renew Part: Transfer case rear output shaft oil seal Quantity: 1  .

5. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Install the transfer case seal dust cover to the flange.

6. NOTE: Check that the circlip is fully engaged.

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Install a new circlip.

   Renew Part: Circlip Quantity: 1  .

7. NOTE:

   • Rotate the differential to engage the splines.
   • Both components need to installed at the same time.

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   • Install the transfer differential assembly.
   • Install the gear.
8. NOTE: Check that the circlip is fully engaged.

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Install a new circlip.

   Renew Part: Circlip Quantity: 1  .

9. NOTE: Make sure that the component is installed to the noted removal position.

   Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   • Install the component.
   • Install the washer.

10. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the bracket.
    • Install and tighten the 2 bolts.

      Torque  : 15Nm 

11. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install the transfer case chain assembly.

12. CAUTION: Make sure that the component is clean and free of foreign material.

    Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install the magnetic filter.

13. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.

    Refer to: SPECIFICATIONS .

14. CAUTION:

    • Make sure that the input shaft spacer is located correctly.
    • The input shaft and fluid pump assembly must be supported and held in place by hand, until it is located securely into the clutch assembly.

    Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install the front half of the transfer case.

15. 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 its transmission mating face down on a flat surface.

16. CAUTION: Only tighten the bolts finger-tight at this stage.

    Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Install and tighten the 19 bolts finger tight.

17. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Tighten the 2 bolts to the correct torque.

    Torque  : 10Nm 

18. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    Fully tighten the 19 bolts.

    Torque  : 35Nm 

19. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the Transmission Control Module (TCM).
    • Install and tighten the 2 bolts.

      Torque  : 35Nm 

20. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the sensor.
    • Install and tighten the 2 bolts.

      Torque  : 5Nm 

21. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the Noise, Vibration and Harshness (NVH) damper.
    • Install and tighten the bolt.

      Torque  : 75Nm 

22. NOTE: This step is only required if previously removed.

    Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the heatshield.
    • Install and tighten the 3 bolts.

      Torque  : 8Nm 

23. NOTE: This step is only required if previously removed.

    Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

    • Install the heatshield.
    • Install and tighten the 2 bolts.

      Torque  : 8Nm 

24. With assistance, release the transfer case from the flat surface.
25. Install the transfer case.

    Refer to: TRANSFER CASE - TDV6 3.0L DIESEL/TDV6 3.0L DIESEL - GEN 1.5/TDV6 3.0L DIESEL - GEN 2 .

    Refer to: TRANSFER CASE - TDV8 4.4L DIESEL 

    Refer to: TRANSFER CASE - V8 S/C 5.0L PETROL .

    Refer to: TRANSFER CASE - INGENIUM I4 2.0L PETROL - PHEV .

    Refer to: TRANSFER CASE - INGENIUM I4 2.0L PETROL .

    Refer to: TRANSFER CASE - INGENIUM I6 3.0L PETROL .

    Refer to: TRANSFER CASE - INGENIUM I6 3.0L PETROL .

26. Make sure the transfer case flange seal cover is install on the flange.

The following step(s) applies to: 

Plug in hybrid electric vehicles only

1. Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC

   Power Up the High Voltage (HV) system. Only technicians qualified to EVAP level are allowed to perform this procedure. It is mandated that all technicians involved with the steps in this procedure have read and understood the Electric Vehicle Safety Rules.

   Refer to: HYBRID ELECTRIC VEHICLE POWER DOWN/UP .

The following step(s) applies to: 

All vehicles

1. • Connect the Jaguar Land Rover approved diagnostic equipment.

     General Equipment: Jaguar Land Rover approved diagnostic equipment 

   • Start the diagnostic service function "transfer case-transfer case control module replacement".
   • Start the service function "transfer case-absolute position sensor replacement".
   • Clear any Diagnostic Trouble Codes (DTCs) after calibration and check for correct operation.