Removing and installing/replacing left output shaft (Cooper Convertible)

IMPORTANT: Manual transmission only:

After each removal of the output shaft, the RADIAL SHAFT SEAL in the transmission must be replaced.

Preliminary work needed:

Remove front WHEEL .
Remove THRUST FIELD .
Manual transmission only: Drain and catch TRANSMISSION OIL .

Removal:

If necessary, lever off protective cap (1).

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Release collar screw (1), press brake pedal to floor for this purpose.

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Turn steering wheel to left.

Pull output shaft (1) out towards front.

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IMPORTANT: Secure output shaft (1) against falling down.

Use a mounting lever (2) to lever the output shaft (1) out of the transmission.

Remove output shaft (1).

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Installation:

IMPORTANT: Manual transmission only:

Replace the RADIAL SHAFT SEAL for the transmission.

IMPORTANT: With automatic transmission only:

Lever out O-ring (1).
Part : Replace O-ring.
Insert new O-ring (1).

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IMPORTANT: Different types of output shafts fitted! Do not mix up snap rings.
M Manual transmission
A Automatic transmission

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Replace snap ring.

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Insert assembly guard (1) into radial shaft seal.

Assembly guard (1) is provided with new radial shaft seal.

Make sure the tool fits over the lip of the radial shaft seal so there is no damage to sealing ring when the output shaft is inserted.

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Insert output shaft (1) into transmission.

Manual transmission only:
Before sealing surface is pushed into radial shaft seal, remove assembly guard (2) by pulling on handle.

Slide output shaft into transmission up to stop.

The output shaft must snap audibly into place.

Check for secure seat by levering.

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Turn steering wheel to left.

Insert output shaft (1) from the front into the pivot bearing.

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Pay attention to installation position of compression spring (2).
Keep collar screw and spur gearing of wheel bearing/output shaft clean and free from grease.

IMPORTANT: Following installation note for spur gearing must be observed without fail!

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Part : Replace collar screw and compression spring.

Tighten collar screw (1) and compression spring hand force.

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Spur gearing of wheel bearing (1) and output shaft (2) must be installed form-fit (tooth in tooth position)!

Check whether spur gearing is locked tooth in tooth by reciprocally rotating wheel hub/output shaft.

Once a form-fit has been ensured, tighten to final torque.

Tightening torque 31 60 2AZ .

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If necessary, attach protective cap (1).

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Required follow-up work:

manual transmission only: Add TRANSMISSION OIL .
- The vehicle must be level when the transmission oil is filled.
Check transmission for leaks.
Install THRUST FIELD .
Install front WHEEL .