Thread: Transfer case bolts?

Can someone please advise the size i.e. number of bolts, length and diameter of all the bolts holding the transfer case in a Tdi defender (R380) to the gearbox. I removed them some time ago and need to put it back together.

Further, if the engine, gearbox and transfer case has been removed what is the easiest sequence to put them back together, gearbox first or engine?

In putting them back in if motor gearbox and transfer are out I would def go gearbox in, then tranfer or gearbox and transfer together and then motor.


Actually thinking about it further the way I do it you can really put them all in in any order without mounting anything and then bolt them to one another in location. The trick is make sure your clutch and pressure plate etc are all aligned really well. And then line your gearbox up nice and true to slide the two together

Check the gap all the way round the bell housing to make sure its all square to the motor. Then I use longer bolts from the motor backing plate off the back corners of the sump as gearbox bolts to pull the two together. Then pull these longer bolts out and fit the proper short ones. Be carefull you dont pull the input shaft in without the splines lined up or bottom out a bolt in a casting if its too long tho.....

Make sure you support the back of the motor too, if you rest it on its engine mounts only as it will want to drop at the back without the gearbox holding it up.

Im sure theres more tricks i use, Oh, in any series/ defender vehicle, uve probably already done it, but the centre floor section removed makes the job soooo much easier. And leave all gear/ transfer levers off till everything is in place in vehicle.