Automatic Transmission

Transfer Case Connecting Sleeve Seals

Note! Some variation in the illustrations may occur, but the essential information is always correct.

Special tools:
999 2615 Hydraulic pump 999 2615 Hydraulic Pump
999 5069 EXTRACTOR 999 5069 Extractor
999 5575 PULLER CYLINDER USED WITH HYDRAULIC PUMP -5576 999 5575 Puller Cylinder Used With Hydraulic Pump -5576
999 5576 HYDRAULIC PUMP 999 5576 Hydraulic Pump
999 5654 Punch 999 5654 Punch
999 5656 Counterhold 999 5656 Counterhold
999 5657 Punch 999 5657 Punch
999 5777 Extractor 999 5777 Extractor

Preparatory work

Removing the bevel gear and snap ring





Remove:
- the bevel gear. See: Bevel gear Bevel Gear
- the circlip in the connecting socket.

Action for worn splines in sleeve




Cut a - 40 mm piece of cardboard and use as protection to prevent grinding chips from ending up in the transaxle. Apply a thick bead of grease or Vaseline on the seal in the sleeve. Press the piece of cardboard against the seal.




Grind a channel in the inside of the socket so the expander 999 5777 Extractor 999 5777 Extractor attaches. The socket can also be heated using a hot air gun or induction heater.

Installing tool




Install expander 5777-1 and connecting rod 5777-2 (these are included: 999 5777 Extractor 999 5777 Extractor ) for the puller cylinder.
999 5575 PULLER CYLINDER USED WITH HYDRAULIC PUMP -5576 999 5575 Puller Cylinder Used With Hydraulic Pump -5576 used with: 999 5576 HYDRAULIC PUMP 999 5576 Hydraulic Pump (foot operated).
Alternatively: 999 2615 Hydraulic pump 999 2615 Hydraulic Pump , which consists of a puller cylinder and a compressed air driven hydraulic pump.

Removal

Removing the connecting socket




Place drain pan underneath the transaxle.
Ensure that the piston rod in the puller cylinder is in the outer position. Position 999 5777 Extractor 999 5777 Extractor between the puller cylinder and the transaxle. Press in the expander so that it enters the channel on the connecting socket.
Apply the puller cylinder. Check that the socket between the transaxle and the puller cylinder is in contact with its support surfaces.
Remove the socket.
Check the mating surface for the connecting socket. The socket must be replaced if there are signs of grooves or corrosion.

Removing the sealing ring for the connecting socket




Remove the sealing ring from the transaxle.
Use: 999 5069 EXTRACTOR 999 5069 Extractor and 999 5656 Counterhold 999 5656 Counterhold.
Check that there are no seal remnants.

Removing the drive shaft sealing ring




Remove the sealing ring for the drive shaft and O-ring for the connector sleeve.
Use a screwdriver.
Check that there are no seal remnants.





Use: Glue, 1161370

Installation

Installing the O-ring and sealing ring





Install:
- a new O-ring for the connector sleeve on the differential housing
- a new sealing ring for the drive shaft.
Lubricate the seal using the wheel bearing grease, P/N 116 1241-3.
Use: 999 5654 Punch 999 5654 Punch.

Installing the sealing ring




Install the sealing ring for the connector seal.
Lubricate the seal using the wheel bearing grease, P/N 116 1241-3.
Use: 999 5657 Punch 999 5657 Punch.
Tap in the seal until the drift bottoms on its stop against the transaxle.

Installing the snap ring and connecting socket





Install:
- the snap ring for the socket
- the socket for the transaxle with the long splined section (2) toward the transaxle.
Use a rubber mallet to knock in the sleeve.

Finishing

Installing the bevel gear
Install the bevel gear. See: Bevel gear Bevel Gear.