Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Land Rover Discovery (2009–2016) Service Manual / Powertrain / Manual Transmission Transaxle and Clutch / Transfer Case - M66 6-Speed Manual AWD- 9HP48 9-Speed Automatic / AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

SPECIAL TOOL(S)

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

PART(S)

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

REMOVAL

NOTES:

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

All vehicles

WARNING:

Do not work on or under a vehicle supported only by a jack.

Always support the vehicle on safety stands.

Raise and support the vehicle.

Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

Vehicles with diesel particulate filter (DPF)

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

All vehicles

CAUTION:

Discard the bolts.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

CAUTION:

This step must be carried out to make sure that the drive pinion nut is correctly tightened on assembly.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Accurately scribe a line to mark the drive pinion shaft to the drive pinion nut and pinion flange.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Measure the depth of the pinion nut on the pinion shaft.

NOTE:

Position cloth to collect fluid spillage.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Special Tool(s): 205-053

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Using a suitable tool, remove the pinion flange.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Special Tool(s): 308-617

CAUTIONS:

  • Make sure that the area around the component is clean and free of foreign material.
  • Take extra care not to damage the mating faces.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Special Tool(s): 308-615, 100-012

INSTALLATION

All vehicles

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

CAUTIONS:

  • Make sure the drive pinion flange scribed marks are aligned.
  • Make sure the mark on the drive pinion nut is never tightened short of the scribed mark on the drive pinion shaft.
  • Make sure the mark on the drive pinion nut is never tightened past the scribed mark on the drive pinion shaft.
  • If the nut is tightened passed the alignment marks do not loosen it again.

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Make sure the pinion flange nut is installed to same the depth as when removed..

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Torque: 10 Nm

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Make sure new Driveshaft bolts are installed.

Renew Part: Driveshaft to front output flange bolts.

Torque: 40 Nm

Vehicles with diesel particulate filter (DPF)

AWD Transfer Case Rear Seal - Vehicles With- Active Driveline (G1660845) / Removal and Installation

Check and top-up the transfer case fluid level.

Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).

    READ NEXT:

     AWD Transfer Case Rear Seal - Vehicles Without- Active Driveline (G1357768) / Removal and Installation

    SPECIAL TOOL(S) REMOVAL NOTES: Removal steps in this procedure may contain installation details. Some variation in the illustrations may occur, but the essential information is always correct.

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