Determine The Locking Ring -Arrow- For The Input Shaft As Follows:

Fig 1: Circlip In Front Of Ball Bearing Of Input Shaft Must Then Be Removed

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-- Determine thickest circlip which can still just be installed and insert it. For the part number.

NOTE:

Begin wit the thickest locking ring.

The following locking rings are available:

Locking Ring Thickness (mm)
3.44	3.47	3.50

-- Mount the spur gear -2- and the needle bearing -21- LEFT FLANGE SHAFT, CLUTCH MODULE, SIDE SHAFT, GEARSHIFT SHAFT AND TRANSMISSION COVER ASSEMBLY OVERVIEW on the output shaft -3-.

Fig 2: Removing Side Shaft From Transmission Cover

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NOTE:

The adjusting shim for positioning the center differential must be determined again when the transmission cover, the spur gear, the spur gear tapered roller bearing or the spacer sleeve are replaced. Refer to ADJUSTING SHIM S .

-- Install the side shaft -1- all the way into the transmission cover.

Tighten the twelve-point bolt -A- for the side shaft -B- on the pinion as follows:

Fig 3: Tightening Pinion Side Shaft Bolt

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-- Mount a twelve-point socket -C- (21 mm) with an extension -D- over the twelve-point bolt -A-.

-- Insert the T40217 with the outer splines -arrow 1- into the inner splines -arrow 2- on the side shaft.

-- Secure the T40217 to the transmission cover with the M8 bolt -arrows-.

Fig 4: Secure T40217 To Transmission Cover With M8 Bolt

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-- Tighten the side shaft twelve-point bolt to the pinion to the tightening specification.

-A- torque wrench

-- Mount the T40215 all the way onto the spur gear -A- for the side shaft and on the output shaft -B-.

Fig 5: Mount T40215 all the way onto spur gear for the side shaft and on output shaft

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NOTE:

The T40217 remains attached to the transmission cover.
The output shaft will be blocked after the special tool is attached and will not turn.

-- Clean the threads on the bolt -A- on the output shaft with a wire brush. Then install and tighten the bolts with locking fluid AMV 185 101 A1 to the tightening specification.

Fig 6: Cleaning Threads On Bolt

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B - Torque Wrench

-- Remove the T40215 and T40217.

-- Lightly coat the cover -A- for the output shaft with oil on the outer circumference and then install it.

Fig 7: Lightly Coat Cover For Output Shaft With Oil On Outer Circumference And Then Install It

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-- Lightly oil outer circumference of new shaft seal for the input shaft.

Fig 8: Lightly Oil Outer Circumference Of New Shaft Seal For The Input Shaft

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-- Fill area between sealing lip and dust lip halfway with sealing grease G 052 128 A1.

-- Drive the new seal in until it is flush without tilting it.