Contents: Removal ⇩ Installation ⇩
Special tool(s)
 | Impact puller 100-012 |
 | Seal Removal Tool (input and output) 308-375 |
 | Impact Puller Adapter 100-012-01 |
 | Fixing tool, output flange 308-701 |
 | Assembly tool 205-081A |
 | Long Arm Puller 308-516 |
 | Assembly Tool, Secondary Drive Flange Seal 308-604 |
 | Impact Puller Adapter 100-012-05 |
Removal
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. Remove the gear shift lever.
For more information, refer to the chapter: Gear Shift Lever (308-06 External controls for manual transmission in block with drive axle/gearbox - Diesel engine ID4 2.4L, Removal and installation).
3.
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.
4. Drain the transmission fluid from the gearbox.
For more information, refer to the chapter: Draining and Filling Transmission Fluid from the Transmission (308-03 Manual Transmission/Transaxle Transmission, General Procedures).
5. Remove the transfer case.
For more information, refer to the chapter: Transfer Case (308-07A Transfer Case - ID4 2.4L Diesel Engine, Removal).
6. Remove the gearbox extension shaft cover. Remove and discard the clamp.
7. Using a suitable tool, remove the transmission extension shaft. Remove the seal.
8. Remove the gearbox console housing. Remove 10 bolts.
9. Using the special tool, remove the output flange fixing bolt.
10. Using special tools, remove the outlet flange.
11. Using special tools, remove and discard the secondary shaft seal.
Installation
1. Using special tools, install the secondary shaft oil seal.
2.
WARNING: Use caution when using the hot air fan. Failure to do so may result in injury.
NOTE: Using a hot air fan, heat the outlet flange to approximately 100°C.
Using special tools, install the gearbox output flange.
- Tighten the bolt (tightening torque 210 Nm).
- Loosen the bolt.
- Apply thread locking compound. Glue
- Tighten the bolt (tightening torque 180 Nm).
3. Install the transmission extension shaft. Install the seal.
4.
NOTE: Make sure the clamp is installed between the extension shaft seal cover tabs and that it is cut flush with the tabs.
Install the transmission extension shaft seal cover.
- 1. Install the cover.
- 2. Install the clamp.
5. Install the gearbox console housing. Tighten the bolts (tightening torque 25 Nm).
6. Install the transfer case.
For more information, refer to the chapter: Transfer Case (308-07A Transfer Case - ID4 2.4L Diesel Engine, Installation).
7. Fill the gearbox with oil.
For more information, refer to the chapter: Draining and Filling Transmission Fluid from the Transmission (308-03 Manual Transmission/Transaxle Transmission, General Procedures).
8. Install the gear shift lever.
For more information, refer to the chapter: Gear Shift Lever (308-06 External controls for manual transmission in block with drive axle/gearbox - Diesel engine ID4 2.4L, Removal and installation).
9. Connect the ground wire to the battery.
For more information, refer to the chapter: Connecting the Battery (414-01 Battery, Battery Mounting and Cables, General Procedures).
Comments on this article