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

Attention! 

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 .
• Only vehicles with (TU0 engine): Disconnect BATTERY GROUND LEAD.

  Observe the next two figures for the identification of the engine.

(TU0 Engine): Positive battery cable (2) and terminal 50 (1) on the starter motor are not protected against contact.

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(TU1 Engine): Positive battery cable (2) and terminal 50 (1) on the starter motor are protected against contact.

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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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Secure output shaft against falling out.

Turn steering wheel to right.

Pull out output shaft (1).

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If necessary, release screws (1) and remove holder (heat shield) (2).

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Unscrew the screws (1).

Pull output shaft (2) out of transmission and remove to one side.

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Installation: 

Attention! 

Manual transmission only: 

• Replace RADIAL SHAFT SEAL .

Attention! 

With automatic transmission only: 

• Lever out O-ring (1).

  Part  : Replace O-ring.

• Insert new O-ring (1).

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Insert assembly guard (1) into radial shaft seal.

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

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.

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.

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Tighten down screws (1).

Tightening torque 31 60 1AZ .

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Turn steering wheel to right.

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 toothing of wheel bearing/output shaft clean and free of grease

Attention! 

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 the wheel bearing (1) and the 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.

Tighten the collar screw once positive locking has been ensured.

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 fluid.
  • The vehicle must be level when the transmission oil is filled.
• Check transmission for leaks.
• Install THRUST FIELD .
• Install front WHEEL .
• Connect BATTERY GROUND LEAD.