Transfer Case Rear Output Seal (G2413350): 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.

Raise and support the vehicle on a suitable 2 post lift.
Refer to: JACKING AND LIFTING
Remove the transfer case.
Refer to: TRANSFER CASE
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.
CAUTION: Make sure the bolt holes are clean and free of swarf.

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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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Use 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 installed 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 installed position of the component prior to removal.

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

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Remove the transfer differential assembly.
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Install the special tool.

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

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Remove the rear output shaft flange.
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Remove and discard the seal.