Pry Out The Input Shaft Seal

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Fig 1: Removing Input Shaft Seal

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-- The locking ring -1- in front of the input shaft ball bearing must then be removed.

Fig 2: Identifying Input Shaft Ball Bearing Locking Ring

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-- Remove the shim -2-.

NOTE:

If it is not possible to remove the locking ring -1-, then remove the center differential's transmission cover first and then move the input shaft forward using a rubber hammer.
The shim -2- must definitely be removed before pressing out the shift shaft package so that it does not slide into the locking ring groove.

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

Fig 3: Locating Center Differential Housing Bolts

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

Fig 4: Placing 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 5: Removing Gear Carrier

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-- Hold the gear carrier -1- by one of the side ribs with pliers and remove it in direction of -arrow A-.

-- At the same time, carefully hit housing -arrow B- alternating from one side to the other using a rubber hammer.

CAUTION:

Do not damage sealing surfaces when doing this.

-- Remove the locking ring -1- and pull off the output wheel/drive wheel -2- from the pinion.

Fig 6: Identifying Output Components

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-- Remove the spacer sleeve -3- and impeller wheel/drive gear -4- from the output shaft. Remove the impeller wheel/drive gear's needle bearing at the same time.

-- Then turn transmission in assembly bracket so transmission cover -D- faces upward.

Fig 7: Identifying Transmission Cover Bolts

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-- Remove the following bolts: -A- (used for mounting the bearing bracket), bolt -B- (for mounting the reverse shaft) and bolt -C- (for the transmission cover) -D- on the transmission housing -E-.

-- Remove the transmission cover -D-, while being careful of the ball bearing on the input shaft (do not tilt the transmission cover when removing it).

NOTE:

The ball bearing that is located at the back of the input shaft has a sliding fit in the transmission cover.

-- Remove the reverse wheel with reverse shaft -1-.

Fig 8: Identifying Transmission Housing Components

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-- Remove the oil catch tray -2- from the bearing bracket -3- -arrows A- and -arrow B-.

-- Remove the magnet -4- and the oil guide element -5- from the transmission housing.

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

Fig 9: Attaching 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.
Pay special attention to synchronizing the reverse gear when removing the shift shaft package. It must not slide off of the output shaft!

-- 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. Make sure the shift shaft package does not get dropped (get another technician to help you).

-- Remove the in- and output shaft and the shift fork group from the transmission housing.