Gear Actuator Module And Hydraulic Pressure Reservoir, Removing And Installing

Special tools and workshop equipment required 

• Assembly Tool: T40305 

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-- Drain the ATF. Refer to ATF, DRAINING AND FILLING .

-- Drain the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- Remove the transmission: Refer to Transmission, Removing and Installing .

-- Remove the transmission fluid pan. Refer to TRANSMISSION FLUID PAN, REMOVING AND INSTALLING .

-- Remove the gear set. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

-- Disconnect the connector -arrow- using the Assembly Tool: T40305  .

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Vehicles without self-locking center differential 

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-- Loosen the bolts -arrow- for the hydraulic pressure reservoir but do not remove.

• If the hydraulic pressure reservoir lifts when loosening the bolts the ATF system is still under pressure.
• In this case the bolts from the Mechatronic must be minimally loosened to reduce the pressure in the ATF system via the sealing surfaces.
• Deactivate the ATF pump and drain the hydraulic pressure reservoir. Refer to ATF PUMP, DEACTIVATING AND DRAINING THE HYDRAULIC PUMP RESERVOIR .

-- Remove the bolts -arrows- and the hydraulic pressure reservoir.

Vehicles with Self-Locking Center Differential 

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-- Loosen the bolts -arrow- for the hydraulic pressure reservoir and bearing bracket but do not remove.

• If the hydraulic pressure reservoir lifts when loosening the bolts the ATF system is still under pressure.
• In this case the bolts from the Mechatronic must be minimally loosened to reduce the pressure in the ATF system via the sealing surfaces.
• Deactivate the ATF pump and drain the hydraulic pressure reservoir. Refer to ATF PUMP, DEACTIVATING AND DRAINING THE HYDRAULIC PUMP RESERVOIR .

-- Remove the bolts -arrows-, the bearing bracket and the hydraulic pressure reservoir.

Continuation for all vehicles 

-- Remove the bolts -1 through 6- and remove the gear actuator module.

Installing 

-- Insert the gear actuator module and tighten the bolts in the sequence -1 to 6- hand-tight.

-- Before installing the hydraulic pressure reservoir, coat the seals and oil filler hole with ATF.

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-- Guide the hydraulic pressure reservoir carefully and evenly into the oil filler hole, and tighten the bolts -arrow- hand-tight.

-- Tighten the gear positioner and pressure reservoir to the tightening specification. Refer to OVERVIEW - GEAR SET .

-- Bring the gear actuator into the basic setting.

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-- Push the gear actuator by hand and turn it at the same time until it engages and determine the current backlash.

-- Install the gear set. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

-- Install the connector with the Assembly Tool: T40305  .

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-- Install the transmission fluid pan. Refer to TRANSMISSION FLUID PAN, REMOVING AND INSTALLING .

Tightening Specifications 

• OVERVIEW - GEAR SET