Defender. Manual — part 181

LUBRICATION

Lubrication is by splash, oil filler/level and drain plugs being located in the main casing.

Internal pressures caused by thermal expansion and contraction are avoided by the use of a plastic breather pipe

venting the interior of the box to atmosphere. The pipe is attached to the top of the high/low selector housing and is

routed in a continuously rising path into the engine compartment where the open end is secured to the engine cylinder

block.

OPERATION

Power Flow - Transfer Box in LOW Range

Power Flow - Transfer Box in HIGH Range

The gearbox output shaft transmits power to the mainshaft input gear which is in constant mesh with one of the

intermediate gears. The intermediate gears are in constant mesh with the high and low range output gears running on

the differential rear shaft.

Power is transmitted to the output shafts via the differential assembly by locking either the high or low range gears to

the differential rear shaft. This is achieved by means of the high/low selector fork, sleeve and splined hub.

Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma -

Transfer Case Draining and Filling

General Procedures

1.

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.

2. Position a container to collect the fluid.

3. NOTE: Clean the area surrounding the transfer case

filler/level plug.

Remove the transfer case filler plug to vent the transfer case

and assist with draining.

4. NOTE: Clean the area surrounding the transfer case fluid

drain plug.

Remove the transfer case fluid drain plug.

5. Allow the fluid to drain.
6. Install the transfer case drain plug and clean any oil residue

from the surrounding area.

Tighten to 30 Nm (22 lb.ft).

7.

CAUTION: The transfer case oil filler plug must not be

used as a transfer case oil level plug. Failure to follow this

instruction may result in damage to the vehicle.

Refill the transfer case with the recommended fluid.

For additional information, refer to:

Specifications

(308-07A

Transfer Case - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -

Puma, Specifications).

8. Install the transfer case filler plug and clean any oil residue

8. Install the transfer case filler plug and clean any oil residue

from the surrounding area.

Tighten to 30 Nm (22 lb.ft).

9. Remove the container.