Loosen NSF wheel bolts Jack up and axle stand car (approx 24 is perfect) Block back wheels e!

o"e NSF wheel

e!o"e under#bod$ pan %iew with the wheel off before re!o"in& the inner wheel arch liner'

e!o"e inner wheel arch NSF ( $ou will see the lower half of the end panel to the &earbox

)isconnect cable and pull throu&h into wheel arch ( !ake secure

Need photo

*ndo +ubilee clip to throttle bod$ and re!o"e air# filter box e!o"e filler plu&

,lace tarpaulin on floor and bucket for fluid *ndo )rain plu& and allow to drain into bucket'

)rain existin& fluid lea"e to drip out

)isconnect Batter$ e!o"e batter$ usin& -.!! socket to release fabric restraint

e!o"e batter$ box ( 4 x /40 torx)

,lace +ack under front of sub#fra!e (center and take the wei&ht) Loosen sub#fra!e bolt on NSF

Loosen Sub#fra!e bolt on NSF

,lace +ack and block of wood under en&ine Support wei&ht Loosen 4 bolts that attach en&ine to upper!ost !ount (Loosen )1 N1/ 231%2)

*sin& +ud&e!ent lower each +ack in turn until $ou are happ$ $ou ha"e sufficient access to the end panel of the box' 4 lowered until the upper!ost -2!! bolt were clear of the en&ine !ount b$ about .#4!!'
Flan&e on en&ine !ount

*pper!ost bolts

*sin& -2!! socket loosen all -2 !! bolts a little at a ti!e as there is a sprin& like effect when all bolts are undone5 *sin& -6!! socket loosen the 2 bolts in the upper ri&ht hand 7uadrant on the end panel (there is a &roup of 4 ( ONLY UNDO THE LEFT HAND 2 BOLTS5 these also i!pact the direct clutch and we don8t want to pla$ with that') 99,lace a tra$ on an old towel on top of the tarpaulin under the end panel and the &earbox as when this is opened it will release fluid'

Need photo

Fro! the en&ine ba$ +ust ri&ht of the en&ine !ount we loosened earlier and usin& a lar&e flat headed screwdri"er use the flan&e to separate the end panel fro! the box5 when this separates it does so with a little force so be careful ( /his is wh$ the bolts were loosened and not re!o"ed $et as it stops the end panel fro! poppin& off and slippin& onto the internal co!ponents'

:hen released it should look like this ;ou can &o ahead and re!o"e the bolts now5 take note that the 2 -6!! bolts ha"e a s!all rubber seal a&ainst the!5 these will need replacin& when put back to&ether ( i picked 2 up fro! a local &earbox specialist as part of a seal kit for about 2 pounds) :ipe up the !ess'

<arefull$ # re!o"e the end panel throu&h the wheel arch !akin& sure $ou look for the end race bearin& as it has been known to be stuck to the inside of the end panel'

ace bearin&

*nclip the wirin& to the sensor and usin& a -0!! socket re!o"e the 2 copper=bron>e bolts holdin& the sensor in place at the botto! of the &earin& ( take note of how this co!es out'

e!o"e the sensor ( clean and put safel$ out of the wa$'

e!o"e the sprin& asse!bl$ surroundin& the re"erse dru! ( takin& note of how it ali&ns around the !ain dru!' (<o!plete fra!e to the rear)'

<arefull$ draw out the !ain dru!5 /his will not be +ust the dru! as it is attached to the clutch and housin& also'

eplace an$ extra &earin& (carefull$) that !a$ be attached to the !ain dru! back into the &earbox as it is not re7uired to be taken out Should look like this

? look at the dru! (Front and

ear)

4n order to re!o"e this back plate we will need to unclip the circlip surroundin& the out ri!

e!o"e this clip to lift out the back plate

:ith the back plate re!o"ed we can see the co!plexit$ 5 7uite outstandin&' :e can lift out the centre piece

Look for the race bearin& when re!o"in& the centre piece Note the position and which wa$ up'

List out the &earin& to re"eal the inner clutch and a first look at the inner workin&s

elease this clip to allow re!o"al of the clutch co!ponents5 keep these as a co!plete unit and re!e!ber which wa$ the$ are facin& in the asse!bl$' 4ts also worth notin& that the$ are all ali&ned5 this will be useful for the re#asse!bl$ <lutch co!ponents

:ith the clutch co!ponents re!o"ed5 re"ealin& the next la$er''

Next is to re!o"e the upper la$er that is sittin& on the !ain dru!' 4 poked a s!all screwdri"er into the holes in the side to release a circlip and the whole asse!bl$ lifted out 4 left it as one piece and put it to the side'

? s!all screwdri"er here released the circlip releasin& the asse!bl$ Lea"in& a +ust the !ain dru! asse!bl$ left'

/his is trick$5 the idea is to re!o"e this circlip5 in order to !ana&e that the entire centre piece needs to be co!pressed into the dru! to allow a decent release' 4 a! not &oin& to put a picture up of how 4 released the circlip as it was not safe and do not reco!!end it to an$one else ( resultin& in !$ needin& to bu$ a new circlip'

<o!press the outer rin& to allow a decent shot at &ettin& the circlip off'

1nce the clip is off $ou can see the sprin& asse!bl$ underneath5 re!o"e when read$'

:ith the sprin& re!o"ed

Lift out the central co!ponent and keep an e$e out for bits of broken seal5 when 4 lifted this ite! out it shredded the seal on the outside ed&e' (/he picture is fro! the underside)

Lea"in& +ust the offendin& piston left to re!o"e5 Just lift it out wipe it down and ha"e a look'

1ne e"erse piston@@''ti!e for a closer look

<racked@@'

,arts 4 needed for rebuild :$nns Black &asket !aker ( &ood for 2A0B de&rees) JFC0A2',4S0JFC0A2'<4 0.5 a replace!ent circlip for the one 4 da!a&ed durin& the co!press the re!o"e bit JFC0A2'1 D0- ( rubber seal kit for the JFC0A2',4S0- and da!a&ed seal fro! the other co!ponent' Altrs /exaco 402N fro! Landro"er dealer' <o!parison of the old and new parts (1ld is on the ri&ht)'

Put back together in reverse or er Putting in the ne! sea"s an circ"i# as $ou go% Take care an goo "uck% )on8t for&et to clean $our ed&es for the new &asket 2nd panel

Eearbox

:ith &asket applied