Disassembly of a manual transmission (Defender 2007+)

Special tool (s)

	Mounting bracket, engine/diff 205-329
	Impact puller 100-012
	Seal remover 308-615
	Rear seal remover/installer. 303-538
	Puller 308-516
	Mounting tool 205-081A
	Slider puller 308-652
	Selector shaft seal remover 308-621
	Hammer adapter 100-012-01
	Seal remover (input and output) 308-375
	Puller, stopper 308-657
	Adapter for 205-071 (thrust plate) 205-071-01
	Mounting Tool, Double Shaft Shaft Seal 308-150
	Installation tool, transmission console case bushing/seal 308-044
	Puller, bearing/pinion 205-310
	Mounting Tool, differential bearing 205-082
	Puller, intermediate shaft bearing outer race 100-012-06
	Hammer adapter 100-012-05
	Lockout Tool, Outlet Flange 308-701

Disassembly

NOTE: Before removing transmission components, mark their position.

1. Disconnect the wire "masses" from the battery.

For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).

2.

WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.

Raise the car and place stands under it.

3. Drain gear oil.

For more information, refer to the chapter: Draining the transmission fluid from the gearbox and filling the transmission fluid into the gearbox (308-03 Manual/Transaxle Transmission, General Procedures).

4. Remove a transmission in the block with the leading bridge.

For more information, see the chapter: Gearbox (308-03 Manual transmission / transmission in a block with a driving axle, Removal).
5. Using special tools, fix a transmission.

6. Using special tools, fix the output shaft flange. Turn out a bolt.

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

8. Remove the input shaft circlip and discard it.

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

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

11.

NOTE: Make sure transmission is enabled.

Turn out a bolt of an intermediate shaft.

12. Remove special tools.

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

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

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

16. Remove 3 left selector fork bolts.

17. Remove the 3 right selector fork bolts.

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

19. Remove 2 stoppers of a shaft of a choice of transfers.

20. Turn out 13 bolts.

21. Using the 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 pin.

25. Using the 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 the special tools, remove the 2nd gear and 1st/2nd gear synchronizer units from the output shaft.

29. Remove the gear selection shaft retainer.

Turn out two bolts.
Remove two inserts.

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

31. Remove the central bearings.

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

33.

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

Remove selectors.

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

34. Together with an assistant, remove the shafts as an assembly.

35. Remove the input shaft.

36. Remove 2 bearing retainers. Remove 8 bolts.

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

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

39. NOTE: Mark component positions when removing.

Remove the components in the order shown.

1. Bolt of fastening of an intermediate gear wheel of a backing.
2. Fastening of an intermediate gear wheel of a backing.
3. Intermediate reverse gear.
4. Roller bearing of the intermediate shaft.

40. Remove the lock plate of the secondary shaft. Turn out 4 bolts.

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

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

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