Disassembling a manual gearbox (Defender 2007+)

Special tool(s)

	Mounting Bracket, Engine/Differential 205-329
	Impact puller 100-012
	Seal Puller 308-615
	Rear Seal Remover/Installer 303-538
	Puller 308-516
	Assembly tool 205-081A
	Slider Puller 308-652
	Selector shaft seal remover 308-621
	Impact Puller Adapter 100-012-01
	Seal Removal Tool (input and output) 308-375
	Puller, stopper 308-657
	Adapter for 205-071 (thrust plate) 205-071-01
	Assembly tool, double lip seal for drive shaft 308-150
	Assembly tool, bushing/seal, transmission console housing 308-044
	Puller, Bearing/Gear 205-310
	Assembly tool, differential bearing 205-082
	Puller, intermediate shaft bearing outer ring 100-012-06
	Impact Puller Adapter 100-012-05
	Locking device, outlet flange 308-701

Disassembly

NOTE: Before removing transmission components, mark their positions.

1. Disconnect the ground wire from the battery.

For more information, refer to the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mounting and Cables, General Procedures).

2.

WARNING: Never work on a vehicle supported only by a jack. Always support the vehicle with special stands.

Raise the vehicle and place supports underneath it.

3. Drain the transmission oil.

For more information, refer to the chapter: Draining and Filling Transmission Fluid from the Transmission (308-03 Manual Transmission/Transaxle Transmission, General Procedures).

4. Remove the gearbox in block with the drive axle.

For more information, refer to the chapter: Gearbox (308-03 Manual transmission/gearbox in block with driving axle, Removal).
5. Using special tools, secure the gearbox.

5. Using special tools, secure the gearbox.

6. Using special tools, secure the secondary shaft flange. Remove the bolt.

7. Using special tools, remove and discard the input shaft seal.

8. Remove the input shaft retaining ring and discard it.

9. Using a special tool, make a hole in the intermediate shaft seal.

10. Using special tools, remove and discard the intermediate shaft seal.

11.

NOTE: Make sure the transmission is engaged.

Remove the intermediate shaft bolt.

12. Remove the special tools.

13. Using special tools, remove the secondary shaft flange.

14. Using special tools, remove the gear selector shaft seal.

15. Using special tools, remove the secondary shaft seal.

16. Remove the 3 left selector fork bolts.

17. Remove the 3 right selector fork bolts.

18. Using the special tools, remove the 3 gear selector shaft stoppers.

19. Remove the 2 gear selector shaft stoppers.

20. Remove 13 bolts.

21. Using special tools, remove the gearbox housing.

22. Remove the magnet.

23. Remove the reverse gear selector.

24. Remove the 1st/2nd gear selector. Remove and discard the pin.

25. Using special tools, remove the 1st and reverse gears from the secondary shaft.

26. Remove the 1st gear bearing.

27. Remove the 1st/2nd gear synchronizer retaining ring.

28. Using special tools, remove the 2nd gear and 1st/2nd gear synchronizer assemblies from the secondary shaft.

29. Remove the gear selector shaft locking plate.

Remove two bolts.
Remove the two inserts.

30. Remove the center bearing mounting plate. Remove the 3 bolts.

31. Remove the center bearings.

32. Remove the 3rd/4th gear selector from the gearbox housing. Disconnect the selector fork from the gear selector shaft.

33.

NOTE: Do not lose the 4 main selector shaft bearings.

Remove the selectors.

1. Remove the main selector.
2. Remove the 5th/6th gear selector.

34. With the help of an assistant, remove the shafts as an assembly.

35. Remove the input shaft.

36. Remove 2 bearing retaining plates. Unscrew 8 bolts.

37. Using the special tool, remove the input shaft bearing.

38. Using the special tool, remove the intermediate shaft bearing.

39. NOTE: When removing, mark the positions of the components.

Remove the components in the order shown.

1. Reverse intermediate gear mounting bolt.
2. Fastening the reverse intermediate gear.
3. Reverse intermediate gear.
4. Intermediate shaft roller bearing.

40. Remove the secondary shaft locking plate. Unscrew 4 bolts.

41. Using special tools, remove the secondary shaft bearing.

42. Using the special tool, remove the outer race of the intermediate shaft bearing.

The original was published on the portal lrman.ru

43. Remove the secondary shaft guide bearing and the 5th gear synchronizer assembly from the secondary shaft. Remove the retaining ring and discard it as no longer needed.