Transfer Case Rear Output Shaft Bearing (G2375897): Removal

NOTE:

This procedure contains illustrations showing certain components removed to provide extra clarity.
This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

The following step(s) applies to:

Plug in hybrid electric vehicles only

WARNING:

If the vehicle has been powered down, do not power up the vehicle until all the bonding points have been tested.
It is the responsibility of the Electric Vehicle Senior Authorised Person (EVSAP) to make sure they comply with any local legislation for work on High Voltages (HV).
The approved Personal Protection Equipment (PPE) must be worn where indicated within this procedure and not removed unless indicated within a step. All items of PPE must be checked for signs of damage before each use, if damaged, replacement PPE must be obtained before doing this procedure.

NOTE:

All Permit To Work (PTW) documents must be kept for a minimum of 5 years.
This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

WARNING: Jaguar Land Rover (JLR) Electric Vehicle Competent Person (EVCP) trained technicians only.

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This procedure involves work on components associated with the High Voltage (HV) system. Only technicians qualified to Electric Vehicle Competent Person (EVCP) level or higher are allowed to do this procedure. It is mandated that all technicians involved with the steps in this procedure have read and understood the Electric Vehicle (EV) Safety Rules.

Refer to: ELECTRIC VEHICLE SAFETY RULES .
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Power Down 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 .
Refer to high voltage electrical connector operation and inspection document before disconnecting any high voltage electrical connectors.
Refer to: HIGH VOLTAGE ELECTRICAL CONNECTOR OPERATION AND INSPECTION .

The following step(s) applies to:

All vehicles

Raise and support the vehicle on a suitable 2 post lift.
Refer to: JACKING .
Remove 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 - V8 S/C 5.0L PETROL .

Refer to: TRANSFER CASE - TDV8 4.4L DIESEL .

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 .
With assistance, secure the transfer case with its transmission mating face down on a flat surface.
NOTE: If equipped.

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- Remove the 3 bolts.
- Remove the heatshield.
NOTE: If equipped.

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- Remove the 2 bolts.
- Remove the heatshield.
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- Remove the bolt.
- Remove the Noise, Vibration and Harshness (NVH) damper.
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- Remove the 2 bolts.
- Remove the Transmission Control Module (TCM).
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- Remove the 2 bolts.
- Remove the sensor.
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Remove the 19 transfer 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.

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Using a soft faced mallet, release the front casing.
Clean the component mating faces.
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Locate the magnetic filter. The filter may have dropped into the front housing in the previous step.
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Remove the transfer case chain assembly.
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- Remove the 2 bolts.
- Remove the bracket.
CAUTION: Note the fitted position of the component prior to removal.

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Rotate the transfer differential assembly to the position shown in the illustration.
CAUTION: Note the fitted position of the component prior to removal.

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- Remove the washer.
- Remove the component.
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Remove and discard the circlip.
CAUTION: Note the fitted position of the component prior to removal.

NOTE: Remove both components at the same time.

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- Remove the transfer differential assembly.
- Remove the gear.
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Install the special tool.

Special Tool(s): JLR-308-927
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Remove and discard the circlip.
CAUTION: Do not use excessive force whilst removing the flange assembly.

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Remove the rear output shaft flange.
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Remove and discard the seal.
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- Use the special tool to remove the bearings.
  Special Tool(s): 303-1119
- Discard the bearing.