Transmission, Disassembling

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-- Place drip tray underneath.

-- Remove the bolt -arrow- and drain the transmission oil.

Fig 1: Locating Transmission Fluid Drain Plug

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-- Secure the transmission holder T40206 to the transmission with the bolts -arrows- and tighten it in the assembly stand.

Fig 2: Secure T40206 To Transmission With Bolts And Tighten It In Assembly Stand

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-- Remove the clutch module. Refer to CLUTCH MODULE .

-- Set the clutch module down carefully, for example on the workbench.

-- Remove the clutch release lever -1- together with the release bearing -2- and the spring -3-.

Fig 3: Identifying Clutch Release Lever Components

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-- Remove the bolts -4-, the locking plate -5- (if equipped) and the guide sleeve -6-.

-- Pry out the input shaft seal.

Fig 4: Removing Input Shaft Seal

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-- Circlip -arrow- in front of the ball bearing of input shaft must then be removed.

Fig 5: Circlip In Front Of Ball Bearing Of Input Shaft Must Then Be Removed

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NOTE:

If it is not possible to remove the locking ring, then remove the transmission cover first and then move the input shaft forward using a rubber hammer.

-- Push the cover -A- for the output shaft in the center and pry it out in direction of -arrow-.

Fig 6: Push Cover -A- For Output Shaft In Center And Pry It Out In Direction Of -Arrow-.

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-- Remove the bolts -A-, -B- and -arrows- that attach the center differential housing -C- to the transmission cover.

Fig 7: Attaching Center Differential Housing To Transmission Cover Using The Bolts

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NOTE:

Not all versions have the double bolts -B- ; allocation.

-- Carefully remove the center differential housing -6-, the pressure spring -3-, the adjusting shim -4- and the plate spring -5-.

Fig 8: Place Center Differential On The Transmission

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-- Remove the center differential -2- and the gear carrier -1-.

If the gear carrier -1- remains in the center differential housing, proceed as follows:

Fig 9: Center Differential Housing, Proceed As Follows

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-- Grip the side ridge on the gear carrier -1- using a pair of pliers and remove it in direction of -arrow A-.

-- Using a rubber hammer, tap the housing on alternating sides -B arrows-.

CAUTION:

Do not damage sealing surfaces when doing so.

Loosen the twelve-point bolt -A- for the side shaft -B- on the pinion as follows:

Fig 10: Tightening Pinion Side Shaft Bolt

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-- Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

-- Insert the T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

-- Secure the T40217 to the transmission cover with the M8 bolt -arrows-.

Fig 11: Securing T40217 To Transmission Cover With M8 Bolt

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-- Remove the side shaft twelve-point bolt on the pinion.

A - torque wrench

-- Mount the T40215 all the way onto the spur gear -A- for the side shaft and on the output shaft -B-.

Fig 12: Mount T40215 all the way onto spur gear for the side shaft and on output shaft

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NOTE:

The T40217 remains attached to the transmission cover.
The output shaft will be blocked after the special tool is installed and will not turn.

-- Loosen the bolt -A- on the output shaft using the T10061.

Fig 13: Cleaning Threads On Bolt

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NOTE:

The bolt -A- has a very high loosening torque (approximately 300 to 350 Nm).

B - Torque Wrench

-- Remove the T40215 and T40217.

-- Remove the side shaft -1- from the transmission cover.

Fig 14: Removing Side Shaft From Transmission Cover

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-- Remove the spur gear -2- for the spur gear and the needle bearing from the output shaft -3-.

-- If equipped, remove the transmission neutral position sensor -G701- -A-.

Fig 15: If Equipped, Remove Transmission Neutral Position Sensor -G701-

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-- Remove the bolt -arrow- and remove the sensor from the cover -B-.

NOTE:

The cover -B- remains installed.
It is not necessary to remove the cap with disassembling and assembling the transmission, if a cap is installed in place of the transmission neutral position sensor.

-- Remove the bolts -1- and pry the selector shaft cover -2- off carefully.

Fig 16: Remove Bolts And Pry Selector Shaft Cover Off Carefully

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-- Raise the selector shaft slightly -arrow A- and remove it -arrow B-.

Fig 17: Lift Gearshift Shaft And Remove It

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-- Then turn transmission in assembly bracket so transmission cover -C- faces up.

Fig 18: Turning Transmission In Assembly Bracket So Transmission Cover Faces Up

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-- Remove the bolts -A- (for the bearing bracket) and the bolts -B- that attach the transmission cover -C- to the transmission housing -D-.

NOTE:

Make sure the bolt -arrow- is a 50 mm steel bolt when installing the transmission cover.

-- Remove the transmission cover -C-.

-- Remove the oil catch tray -1- from the gearshift rail / shift fork for 3rd and 4th gears -2- and from the bearing bracket -3- -arrows A through D-.

Fig 19: Removing Oil Catch Tray From Gearshift Rail / Shift Fork For 3Rd And 4Th Gears

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-- Attach the T40213 to the T40206 using the bolts -arrows-.

Fig 20: Attach T40213 To The T40206 Using Bolts

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CAUTION:

There is a danger of causing damage to the toothed gears, the shafts and bearings.

The input and output shafts must be removed together.
It is permissible to remove the shaft alternating from side to side by turning each spindle maximum one turn.

-- Remove the input and output shafts from the ball bearings inside the transmission housing by turning the spindles on the T40213 one turn and alternating from side to side.

-- At the same time, remove the reverse shaft support -2- from the transmission housing -arrow B-.

Fig 21: Installing Reverse Drive Gear And Reverse Shaft Support

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-- Remove the reverse drive gear -1- and the reverse shaft support -2- from the drive axle.

-- Remove the input shaft -1- and the output shaft -2- together with the shift fork group -3- from the transmission housing.

Fig 22: Installing Input Shaft And Output Shaft Together With Shift Fork Group

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-- Remove the oil catch tray -4- and the magnet -5-.