Output shaft seal — removal and installation (Defender 2007+)

Special tool (s)

	Impact puller 100-012
	Seal remover (input and output) 308-375
	Hammer adapter 100-012-01
	Locking tool, outlet flange 308-701
	Mounting tool 205-081A
	Long arm puller 308-516
	Mounting Tool, Secondary Drive Flange Seal 308-604
	Hammer adapter 100-012-05

Removing

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. Remove the shift lever.

For more information, see the chapter: Shift Lever (308-06 Manual Transaxle/Gearbox External Controls - ID4 2.4L Diesel Engine, Removal - Refitting).

3.

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.

4. Drain the transmission fluid from the gearbox.

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).


5. Remove the transfer case.

For more information, see chapter: Transfer box (308-07A Transfer case -Diesel engine ID4 2.4L, Removal).

6. Remove the transmission extension shaft cover. Remove and discard clamp.



7. Using a suitable tool, remove the transmission extension shaft. Remove the seal.



8. Remove the case of the console of a transmission. Remove 10 bolts.



9. Using the special tool, remove the outlet flange retaining bolt.




10. Using the special tools, remove the outlet flange.



11. Using the special tools, remove and discard the output shaft seal.

Installation

1. Using the special tools, install the output shaft seal.



2.

WARNING: Be careful when using the hot air fan. Failure to follow this instruction may result in injury.

NOTE: Use a hot air blower to heat the outlet flange to approximately 100°C.

Using the special tools, install the transmission output flange.

• tighten bolt (tightening torque 210 Nm).
• Loosen the bolt.
• Apply threadlocker.glue
• tighten bolt (tightening torque 180 Nm).

3. Install the transmission extension shaft. Install the seal.



4.

NOTE: Make sure the yoke fits between the tabs on the extension shaft seal cover 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. Establish the case of the console of a transmission. Tighten the bolts (tightening torque 25 Nm).




6. Install the transfer case.

For more information, see chapter: Transfer box (308-07A Transfer Case -ID4 2.4L Diesel Engine, Installation).

7. Fill the gearbox with 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).

8. Install the shift lever.

For more information, see the chapter: Shift Lever (308-06 Manual Transaxle/Gearbox External Controls - ID4 2.4L Diesel Engine, Removal - Refitting).

9. Connect the wire "masses" to the battery.

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