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Accueil/Land Rover/Jaguar User Manual Handbook/Range Rover Sport / L494 2017 MANUAL TRANSMISSION/TRANSAXLE, CLUTCH AND TRANSFER CASE USER MANUAL

Range Rover Sport / L494 2017 MANUAL TRANSMISSION/TRANSAXLE, CLUTCH AND TRANSFER CASE USER MANUAL

308-07A: Four-Wheel Drive Systems

Specification

FOUR-WHEEL DRIVE SYSTEMS (G1509690)

SPECIFICATIONS

Torque Specifications

NOTE:

* New bolts must be used when a new component is installed.

DESCRIPTION	NM	LB-FT
* Transfer case shift motor bolts	35	26
* Transfer case clutch control solenoid bolts	5	4
* High/Low range position sensor bolts	5	4
Transmission undershield M10 bolts	60	44
Transmission undershield M6 bolts	10	7
Transmission support crossmember M12 bolts	110	81
Transmission support crossmember M8 bolt	24	17

Removal and Installation

TRANSFER CASE CLUTCH SOLENOID (G1960606)

REMOVAL AND INSTALLATION

41.30.08
SOLENOID - CLUTCH CONTROL - RENEW
ALL DERIVATIVES
0.20
USED WITHINS

PART(S)

STEP	PART NAME	QUANTITY
Installation Step 1	Transfer Case Clutch Solenoid kit	1

REMOVAL

WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

Drain the transfer case.
Refer to:Transfer Case Draining and Filling (308-07C Transfer Case - [+] Twin Speed Transfer Case, General Procedures).

CAUTION:

Connect the diagnostic tool, prior to removal of the solenoid. Carry out the diagnostic service function transfer case – solenoid replacement.
NOTES:
- Some fluid spillage is inevitable during this operation.
- Note the orientation of the electrical connector prior to removal.

INSTALLATION

CAUTIONS:
- Failure to energize the solenoid to aid installation of the arm, may result in damage to the shift fork once the component is installed and the system is operated.
- Make sure the seal is installed correctly.
- Make sure that new bolts are installed.
- Make sure that the electrical connector is installed in the correct orientation as noted in the removal step.
- Make sure that the component sits flush to the transfer case.
NOTE:

Tighten the retaining bolts evenly and progressively.

Connect the electrical connector and energize the solenoid (use the service function transfer case – solenoid replacement to assist with energizing the solenoid) to allow the arm to extend and correctly locate into the shift fork.
Renew Part: Transfer Case Clutch Solenoid kit Quantity: 1.

Torque: 5Nm

Fill the transfer case.
Refer to:Transfer Case Draining and Filling (308-07C Transfer Case - [+] Twin Speed Transfer Case, General Procedures).

Using the approved diagnostic equipment, clear all diagnostic trouble code(s) (DTCs) and check for correct operation.

FOUR-WHEEL DRIVE SYSTEMS

HIGH/LOW RANGE SENSOR (G2003291)

REMOVAL AND INSTALLATION

41.30.07
SENSOR - POSITION - HI/LOW RATIO - RENEW
ALL DERIVATIVES
0.30
USED WITHINS

REMOVAL

NOTE:

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

Disconnect the battery ground cable.
Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

Remove the heat shield if installed.

Disconnect the electrical connector.

Remove the sensor.

INSTALLATION

- Install the sensor.
- Torque: 5Nm

Connect the electrical connector.

- Install the heat shield if previously removed.
- Torque: 8Nm

WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

Connect the battery ground cable.
Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

- Connect the Land Rover approved diagnostic equipment.
- Start the service function "transfer case-absolute position sensor replacement".
- Clear any Diagnostic Trouble Codes (DTCs) after calibration and check for correct operation.

FOUR-WHEEL DRIVE SYSTEMS

TRANSFER CASE CONTROL MODULE (G2469183)

REMOVAL AND INSTALLATION

REMOVAL

NOTES:

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.

Disconnect the startup battery ground cable.
Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

Raise and support the vehicle on a suitable 2 post lift.
Refer to:Lifting (100-02 Jacking and Lifting, Description and Operation).

NOTE:

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

Disconnect the electrical connector.

- Remove the 2 bolts.
- Remove the Transfer Case Control Module (TCCM).

INSTALLATION

- Install the TCCM.
- Install and tighten the 2 bolts.
  Torque: 18Nm
- Connect the electrical connector.

NOTE:

If equipped.
- Install the heatshield.
- Install and tighten the 3 bolts.
  Torque: 8Nm

Connect the startup battery ground cable.
Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

- Connect the Jaguar Land Rover (JLR) approved diagnostic equipment.
- Start the diagnostic service function "transfer case-transfer case control module replacement".
- Clear any Diagnostic Trouble Code(s) (DTC) after calibration and check for correct operation.

308-07B: Transfer Case - [+] Single Speed Transfer Case

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE (G1606372)

SPECIFICATIONS

Sealants and Lubricants

ITEM	SPECIFICATION
* Recommended oil	Castrol BOT850
Capacity - Wet and dry fill	0.75 litres, (1.3 pints) (0.8 US quarts)
Input shaft splines grease	Weicon TL7391
Transfer case sealant	TL 7990 Hylomar black 102 or equivalent

CAUTION:

* Do not use any lubricant other than that specified

ITEM	SPECIFICATION
Model	ITC Torsen
Type	Single speed, permanent four wheel drive transfer box with 42 front / 58 rear (± 20% to either axle, dependant on traction ) torque split across the centre differential
Ratio	1:1

Torque Specifications

DESCRIPTION	NM	LB-FT
Transfer case fluid drain plug	28	21
Transfer case fluid filler/level plug	28	21
Transmission support insulator to transfer case bolts	60	44
Transfer case to transmission bolts	45	33
Transfer case bolts	35	26
Wiring bracket bolts	25	18
Earth strap bolt	25	18
* Front driveshaft to transfer case output flange:
Stage 1	45	33
Stage 2	Further 90°	Further 90°

* New 'patched' Torx bolts must be installed

Description and Operation

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE (G1607038)

DESCRIPTION AND OPERATION

COMPONENT LOCATION

ITEM	DESCRIPTION
1	Single speed transfer case

OVERVIEW

The new Single speed Transfer Case is standard fitted for V6 Petrol and V6 Diesel engines. (Twin speed Transfer Case is optional.)

The Single speed transfer case is full time, permanent four-wheel-drive unit, with 40/60 torque distribution to the front and rear driveshafts.

Common components with Twin-speed Transfer Case:

Front and Rear Flanges
Main Seals
Main Bearings
Fill/Drain Plugs
Fixings and Torques
Breather
Tachograph encoder (optional)

The improvements of the new Single speed Transfer Case are the following:

Different oil specification - Castrol BOT850 with friction modifier
Reduced Complexity
No electronic controls
Optimized dynamic vehicle behavior

The Single speed TC consists of 25 components, the weight and inertia were reduced for improved economy.

A unique type of grease, Weicon anti-seize montagepaste grau TL 7391, must be applied to the transfer case input shaft spline when installing the transfer case.

ITEM	DESCRIPTION
1	Input shaft spline

SYSTEM OPERATION

The torque input from the transmission is passed to the transfer case input shaft. The input shaft connected directly to the differential coupling. The differential coupling connects to the housing which splits the torque between the internal gear and the sun gear by the six planetary gears. The internal gear is connected and passes the torque to the rear output flange. The sun gear is connected to the chain drive sprocket and passes the torque to the front output flange via the chain.

The center differential responds to the torque changes at the axles. The basic torque distribution between the front and rear axles is 40/60% at normal drive conditions. If an axle loses traction, the driving torque is redirected instantaneously to the other axle between 65/35% Front/Rear and 20/80% Front/Rear.

DESCRIPTION

TRANSFER CASE - SECTIONAL VIEW

ITEM	DESCRIPTION
1	Input shaft
2	Drive chain sprocket
3	Center differential cap
4	Friction washer
5	Planetary gear (6 off)
6	Center differential internal gear
7	Rear output flange
8	Center differential coupling
9	Center differential sun gear
10	Rear housing assembly
11	Drive chain
12	Drive chain sprocket - Front output
13	Front output flange
14	Front housing assembly

TRANSFER CASE POWER FLOW

Input torque from the transmission is transferred to the input shaft of the transfer case and then onto the differential coupling. The coupling is connected to the differential housing. The planetary gears are held in place by the differential housing, which are connected to the differential internal gear, and the sun gear. The torque is then distributed to both the differential internal gear, and the sun gear, which are connected to the outputs of the transfer case. The internal gear is connected directly to the rear output flange, the sun gear is connected directly to the drive chain sprocket and therefore to the chain drive, which provides front output flange rotation.

Front Casing Assembly

The front casing assembly provides the location for the input shaft bearing and the front output flange bearing. It is also equipped with threaded holes to mount the chassis mounting bush, 2 lifting eyes and a breather cartridge for the transfer case breather pipe. The breather pipe allows equalization between atmospheric and internal transfer case pressure.

The front casing has an additional boss cast on the inside. The boss is used to mount two snubbers - one on drive side of the chain and one on the coast side - which are secured with 2 screws. The snubbers are suppressing chain vibrations which can occur under medium acceleration conditions, therefore improving NVH (Noise, Vibration and Harshness) issues. During normal operation the chain does not contact the snubbers.

Rear Casing Assembly

The rear casing assembly provides the location for the rear output flange bearing, the oil fill and drain plug. Fins are cast into the rear casing assembly to improve heat dissipation. The part number & serial number are printed on a bar code label.

Chain Drive

The chain-drive transfers drive from the center differential to the front output flange. A 3/8" pitch chain connects the sprocket on the transfer case input shaft with the sprocket on the front output flange. As both sprockets have the same number of teeth, the rotational speed of both sprockets is identical. During the vehicle operation the chain delivers the oil upwards and provides the lubrication for the input shaft, the output flange bearings, and the center differential assembly.

NOTE:

When installing or replacing the chain, the BLUE guide links must be facing the center differential, towards the rear output flange.

Center differential

ITEM	DESCRIPTION
1	Drive chain
2	Center differential cover
3	Fixing nut
4	Planetary gear (6 off)
5	Center differential internal gear
6	Center differential housing
7	Coupling
8	Rear output shaft
9	Center differential sun gear
10	Drive chain sprocket
11	Friction washer
12	Input shaft

The center differential assembly is the primary feature of the transfer case. Torque is transmitted through the center differential coupling and housing, and distributed by the planetary gear set to the differential gears and the front and rear output flanges.

The assembly comprises 6 planetary gears, which are equally spaced within the center differential housing. The planetary gears are supported in both directions by the differential casing and the differential cap.

The different basic torque distribution results from the different circle diameters of the internal gear and the sun gear. If an axle loses traction, the bias between the casing, the planetary gears and the cap generates internal friction inside the differential, and the torque directed to the other axle.

Diagnosis and Testing

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE (G2001812)

DIAGNOSIS AND TESTING

PRINCIPLES OF OPERATION

For a detailed description of the Transfer Case - Single speed, refer to the relevant Description and Operation section in the workshop manual. REFER to:Transfer Case (308-07B Transfer Case - [+] Single Speed Transfer Case, Description and Operation).

INSPECTION AND VERIFICATION

CAUTION:

Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.

NOTES:

If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation of a new module/component.
When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into account.
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

Verify the customer concern
Visually inspect for obvious signs of damage and system integrity

Visual Inspection

MECHANICAL
Transfer case Driveshafts Differentials Halfshafts Fluid leaks

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index
Check JLR claims submission system for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific customer complaint and carry out the recommendations as required.

SYMPTOM CHART

SYMPTOM	POSSIBLE CAUSES	ACTION
Warning message/gearbox fault displayed on instrument cluster	Transfer case system fault	Using the manufacturer approved diagnostic system, perform routine - Inline diagnostic unit 2 non-intrusive test -Transfer case Pass - Recheck operation Fail - Refer to the relevant DTC index
Whining noise	Transfer case bearing/chain wear	Using the manufacturer approved diagnostic system, perform routine - Noise, vibration and harshness sensor diagnostic test - Transfer case Refer to the relevant section of the workshop manual and install a new transfer case chain Refer to the relevant section of the workshop manual and install a new transfer case rear output shaft bearing

JUDDER DURING LOW SPEED MANOEUVRING WITH HIGH STEERING INPUTS

At full lock, there will be some tyre scrubbing; as the temperature drops, scrubbing may be experienced as stick/slip judder. This is normal and does not require any service intervention

VIBRATION FROM TRANSFER CASE

Vibration from the transfer case may be caused by the installation of incorrect front/rear drive units. Refer to Sections 205-02 and 205-03 for further guidance on how to diagnose and rectify this issue

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE

TRANSFER CASE OIL COLOR CHARTS (G2723410)

DIAGNOSIS AND TESTING

OIL CONDITION ACCEPTABLE - OK

OIL CONDITION SYMPTOM	OIL CONDITION ACCEPTABLE - OK
Clutch Material - Clutch material will cause blackening of oil. This can be seen as streaks of black sediment as seen in illustration E266765. This can be seen well in oil slosh test. Definition of sediment can also be improved in the filtration process.	Oil Acceptable - OK
Drain Plug - The transfer case drain plug is not magnetic. There is a magnet set internally of the casting. Chain and sprocket wear will cause a significant amount of filing during wear. This should be picked up by the magnet however there may still be small amount of metallic filings in the oil.	Oil Acceptable - OK
Oil Color - Oil Will often start with a golden color which after run in procedures which will blacken quick due to run in procedure material. Oil will continue to blacken after this and even at high milege coloration change from golden to more gray/back tones (D7u Transfer case example on left. This can be seen across oil ranges.	Oil Acceptable - OK

Oil Condition Not Acceptable - NOK

OIL CONDITION SYMPTOM	OIL CONDITION NOT ACCEPTABLE - NOK
NOTE: Aluminum in Oil will usually be from the casting process. Confirm that there are materials in the oil. Take high definition photos of material in oil and raise a Technical Assistance (TA) with the supporting information.	Oil Not Acceptable - NOK
Water in oil will cause separation of the oil as seen on illustration E266791 (more relevant to units with clutch plates). Oil Change / Confirm the repair and check for location of water ingress( casting split line, seals, breathers, local breather) / in no confirmation of the repair replacement may be requred.	Oil Not Acceptable - NOK
Cause - Large pieces of clutch material may be a sign of Failed clutch or delamination. Confirm that there are materials in the oil. Take high definition photos of material in oil and raise a TA with the supporting information.	Oil Not Acceptable - NOK
Cause - Large Pieces of ferrous metal in the oil would suggest failure of internal components. Gear failures may cause/produce shards of metal in the oil. Alternatively bearing failures will also deposit bearing material in to the oil. Confirm materials in drain plug. Take high definition photos of the material on the drain plug. Take high definition photos of material in oil and raise a TA with the supporting information.	Oil Not Acceptable - NOK IS THIS THE CORRECT IMAGE? AS THE TEXT REFERS TO DRAIN PLUGS?
Cause - Thickened oil with a consisted black color can be caused by burnt oil. Burnt oil: When the oil is overheated or there is damage to the clutch plates the oil develops a strong burnt smell. This smells like burnt clutch or brake material. Smell the oil to check for burnt smell. Confirm darkness is not from clutch sediment only. Look through side gear holes to confirm if there is an even black coat of burnt oil on the internals. Take high definition photos of material in oil and raise a TA with the supporting information.	Oil Not Acceptable - NOK

General Procedures

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE

TRANSFER CASE DRAINING AND FILLING (G1606373)

GENERAL PROCEDURES

41.20.04
TRANSFER GEARBOX DRAIN AND REFILL
SINGLE SPEED TRANSFER CASE
0.20
USED WITHINS

41.20.04
TRANSFER GEARBOX DRAIN AND REFILL
TWIN SPEED TRANSFER CASE
0.20
USED WITHINS

PART(S)

STEP	PART NAME	QUANTITY
Draining Step 5	Transfer case drain plug washer	1
Filling Step 3	Transfer case fill plug washer	1

DRAINING

NOTE:

Some variation in the illustrations may occur, but the essential information is always correct.

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.

Position a container to collect the fluid.

CAUTION:

Make sure that the area around the component is clean and free of foreign material.

NOTE:

Remove and discard the sealing washer.

Allow the fluid to drain.

NOTES:
- Make sure that all the component mating faces are clean.
- Install a new sealing washer.
Renew Part: Transfer case drain plug washer Quantity: 1.

Torque: 28Nm

FILLING

CAUTION:

Make sure that the area around the component is clean and free of foreign material.

NOTE:

Remove and discard the sealing washer.

Refill transfer case with the recommended fluid, until the fluid is level with bottom of filler/level plug hole.

NOTES:
- Make sure that all the component mating faces are clean.
- Install a new sealing washer.
Renew Part: Transfer case fill plug washer Quantity: 1.

Torque: 28Nm

Removal and Installation

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE

TRANSFER CASE FRONT OUTPUT SEAL (G2003498)

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

205-818

Installer, Seal

308-620

Installer, Seal

308-636

Installer

JLR-308-926

Support Tool, Transfer Case

JLR-308-933

Remover, Transfer Case Flange

PART(S)

STEP	PART NAME	QUANTITY
Installation Step 2	Transfer case front output seal and bearing kit	1

REMOVAL

NOTE:

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

Disconnect the battery ground cable.
Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

WARNING:

Make sure to support the vehicle with axle stands.

Raise and support the vehicle.

Drain the transfer case fluid.
Refer to:Transfer Case Draining and Filling (308-07C Transfer Case - [+] Twin Speed Transfer Case, General Procedures).

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 (308-07B Transfer Case - [+] Single Speed Transfer Case, Removal).

Refer to:Transfer Case - V6 S/C 3.0L Petrol (308-07B Transfer Case - [+] Single Speed Transfer Case, Removal).

Refer to:Transfer Case - INGENIUM I4 2.0L Diesel (308-07B Transfer Case - [+] Single Speed Transfer Case, Removal).

CAUTION:

Make sure the bolt holes are clean and free of foreign materials.

Remove the 17 transfer box case bolts.

WARNING:

Eye protection must be worn.

CAUTION:

Care must be taken to avoid damage to the mating surfaces.

Using a soft faced mallet, release the rear casing.

Split the transfer box case.

CAUTION:

Make sure that the mating faces are clean and free of foreign material.

Remove the sealant from the transfer case mating faces.

CAUTION:

Note the installed position of the component prior to removal.

CAUTION:

Note the installed position of the component prior to removal.

Remove the transfer case chain assembly.

CAUTION:

Note the installed position of the component prior to removal.

Remove the spacer.

Install the special tool.
Special Tool(s): JLR-308-926

CAUTION:

Make sure that the special tool is correctly located. This will make sure that the snap ring is fully compressed during the next step.

Release the snap ring using the special tool.
Special Tool(s): JLR-308-933

CAUTION:
- Do not use excessive force whilst removing the flange assembly.
- Discard the snap ring.
Remove the transfer case front output shaft.

Remove and discard the seal.

Remove the bearing.

INSTALLATION

Position the special tool as shown, to support the transfer case during the next step.
Special Tool(s): JLR-308-926

CAUTION:
- The chamfer on the bearing inner track must face the seal.
- The transfer case must be supported by the special tool on a flat surface during this step.
- Install the bearing.
  Special Tool(s): 308-620
- Renew Part: Transfer case front output seal and bearing kit Quantity: 1.

- Install the seal.
  Special Tool(s): 308-636

- Centralise the snap ring in the snap ring groove before installing the output flange.
- Extreme care is necessary to make sure the snap ring enters the bearing squarely.
- Install a new snap ring.
- Using the special tool and with assistance, install the drive flange.
  Special Tool(s): 205-818

NOTE:

Make sure that the component is installed to the noted removal position.

Install the spacer.

CAUTION:

The dark links in the chain face up as shown.

NOTE:

Make sure that the components are installed to the noted removal position.

Install the transfer case chain assembly.

NOTE:

Make sure that the component is installed to the noted removal position.

Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.
Refer to:Specifications (308-07A Four-Wheel Drive Systems, Specifications).

CAUTION:

Only tighten the bolts finger-tight at this stage.

Install the 17 transfer box case bolts.

Torque: 10Nm

Torque: 35Nm

Install the transfer case.
Refer to:Transfer Case - TDV6 3.0L Diesel /TDV6 3.0L Diesel - Gen 1.5/TDV6 3.0L Diesel - Gen 2 (308-07B Transfer Case - [+] Single Speed Transfer Case, Installation).

Refer to:Transfer Case - V6 S/C 3.0L Petrol (308-07B Transfer Case - [+] Single Speed Transfer Case, Installation).

Refer to:Transfer Case - INGENIUM I4 2.0L Diesel (308-07B Transfer Case - [+] Single Speed Transfer Case, Installation).

Fill the transfer case with the recommended fluid.
Refer to:Transfer Case Draining and Filling (308-07C Transfer Case - [+] Twin Speed Transfer Case, General Procedures).

Connect the battery ground cable.
Refer to:Specifications (414-00 Battery and Charging System - General Information, Specifications).

TRANSFER CASE - [+] SINGLE SPEED TRANSFER CASE

TRANSFER CASE REAR OUTPUT SEAL (G2006820)

REMOVAL AND INSTALLATION

41.20.54
OIL SEAL(S) - REAR OUTPUT SHAFT - RENEW
3000 CC, TDV6, DIESEL, SINGLE SPEED TRANSFER CASE, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST
2.60
USED WITHINS

41.20.54
OIL SEAL(S) - REAR OUTPUT SHAFT - RENEW
3000 CC, TDV6, DIESEL, TWIN SPEED TRANSFER CASE, WITH PARTICULATE FILTER, WITH DIESEL EXHAUST FL
3.40
USED WITHINS

SPECIAL TOOL(S)

204-525-1

Replacer, Drive Flange

205-726

Remover/Installer, Wheel Hub Bearing

308-637

Installer

JLR-308-927

Support Tool, Transfer Case