Defender. Manual — part 189
Name
Silicone Sealant
Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -
Transfer Case
Installation
Special Tool(s)
Powertrain Assembly Jack
HTJ1200-02
Transfer Case Support
100-045
Materials
Specification
WSE-M4G323-A4
Installation
1. With assistance, install the transfer case.
Apply sealant to the bolt threads.
sealant
Tighten the bolts to 45 Nm (33 lb.ft).
Tighten the nuts to 45 Nm (33 lb.ft).
2. NOTE: Lower the transmission jack.
Install the right-hand transfer case mount.
Tighten the bolts to 85 Nm (63 lb.ft).
Tighten the nut 48 Nm (35 lb.ft).
3. Remove the special tool.
3. Remove the special tool.
4. Remove the special tool.
5. Install the bolts.
Apply sealant to the bolt threads.
sealant
Tighten to 25 Nm (18 lb.ft).
6. Secure the transmission wiring harness.
Tighten to 45 Nm (33 lb.ft).
7. Install the differential lock control operating rod.
7. Install the differential lock control operating rod.
Tighten the nut to 25 Nm (18 lb.ft).
8. Install the new retaining clip at the lower end of the pivot
arm.
9. NOTE: Make sure the rod is fully engaged on the ball joint.
Connect the high/low range selector rod.
10. Connect the differential lock detection switch electrical
connector.
1. Connect the electrical connector.
2. Secure the electrical connector to the bracket.
11. Connect the differential lock warning lamp electrical
connector.
1. Connect the electrical connector.
2. Secure the electrical connector to the bracket.
12. NOTE: Remove and discard the blanking caps.
12. NOTE: Remove and discard the blanking caps.
Install the transfer case breather pipe bolt.
Install new sealing washers.
Tighten the bolt to 15 Nm (11 lb.ft).
13. Tighten to 12 Nm (9 lb.ft).
14. Tighten to 45 Nm (33 lb.ft).
15. Connect the electronic speedometer electrical connector to
the transfer case.
16. NOTE: Remove and discard the tie strap.
Tighten to 45 Nm (33 lb.ft).
Align the position of the driveshaft in relation to the
drive pinion flange.
17. NOTE: Install new nuts.
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