Shift Shaft Seal, A/T

SEAL - SELECTOR SHAFT

Remove

1. Position vehicle on a four post lift.
2. Release fixings from battery cover and remove cover.
3. Disconnect battery earth lead.





4. Petrol models: Release clips securing cooling fan cowl and remove cowl.





5. Petrol models: Remove 3 bolts securing engine RH lifting eye to cylinder head and position earth strap and lifting eye aside.
6. Remove window switch pack.





7. With the handbrake released, remove clip and clevis pin securing handbrake cable to handbrake.
8. Raise vehicle and release handbrake cable and grommet from tunnel.
9. Petrol models: Remove exhaust front pipe.
10. Diesel models: Remove chassis crossmember.





11. Remove 4 bolts securing transmission mounting assembly and remove assembly.





12. Remove 4 bolts securing rear propeller shaft guard and remove guard.
13. Raise one wheel on each axle to allow rotation of propeller shafts.
14. Mark transfer box and propeller shaft flanges to aid re-assembly.





15. Remove 4 bolts from each propeller shaft flange.
16. Release propeller shafts and tie aside.
17. Lower gearbox for access.





18. Remove split pin securing gear selector cable trunnion to gear selector lever and release trunnion.
19. Remove 2 bolts securing gear selector cable abutment bracket and harness support bracket to gearbox.
20. Position selector cable and bracket aside.
21. Lower gearbox support to gain access to selector shaft.
22. Remove valve block.





23. Disconnect harness from gear selector switch multiplug and release multiplug from bracket.
24. Remove nut securing selector shaft lever and release lever from shaft.
25. Remove bolt and nut securing gear selector switch to gearbox and remove switch.





26. Drift out and discard selector quadrant roll pin. Remove selector shaft.
27. Remove selector quadrant and connecting rod.
28. Remove oil seal taking care not to damage seal housing.

Refit

29. Clean shaft and seal housing.
30. Using a suitable adapter, fit new seal.
31. Fit selector quadrant and connecting rod.
32. Fit selector shaft and secure to quadrant using new roll pin.
33. Fit valve block.
34. Position selector switch and tighten nut and bolt.
35. Position selector shaft lever and tighten nut.
36. Fit selector switch multiplug to bracket and connect harness to multiplug.
37. Align harness support bracket and gear selector cable abutment bracket to gearbox and secure with bolts.
38. Connect gear selector cable bunion to lever and fit split pin.
39. Adjust gear selector cable.
40. Raise gearbox on transmission jack.
41. Fit handbrake cable through transmission tunnel.
42. Clean propeller shaft and transfer box flanges.
43. Fit shafts to transfer box flanges, align marks and tighten nuts and bolts to 48 Nm (35 ft. lbs.).
44. Fit rear propeller shaft guard and secure with bolts.
45. Fit transmission mounting assembly and tighten bolts to 44 Nm (33 ft. lbs.).
46. Diesel models: Fit chassis crossmember.
47. Petrol models: Fit exhaust front pipe.
48. Connect handbrake cable to lever and fit clevis pin and clip.
49. Fit window switch pack.
50. Petrol models: Fit engine RH lifting eye, align earth strap and secure with bolts.
51. Petrol models: Fit cooling fan cowl and secure with clips.
52. Connect battery earth lead.
53. Fit and secure battery cover.