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VT2-VT3 for Haima ZZ. Service Manual - part 3

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Fig. 1-3: Drive shaft inserted for 4cm

-Stop and leave 2 cm distance between the driveshaft and mounting tool:

Fig. 1-4: 2 cm distance between drive shaft and tool 480145

-Remove the tool 480145

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Fig. 1-5: Tool 480145 removed

-Push driveshaft completely into the transmission:

Fig. 1-6: Drive shaft mounted

2.6.2.2. Replacing differential seal

When:
In case of damage/leakage on seal or half shaft.
How:
-Drain the oil of the transmission (see changing oil filter)
-Remove half shaft
-use a big screwdriver to pinch out the seal. Be careful not to put screwdriver in too
deep，otherwise the housing can be damaged by the tip of the screwdriver (see Fig.
2-1)
-Discard the old oil seal

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Fig. 2-1: Remove oil seal

Fig. 2-2: Installing new seal with special tool

2.6.2.3. Replacing input shaft seal

When:
In case of damage or leakage on seal
How:
-Drain the oil of the transmission (see changing oil filter)

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Fig. 3-1: Remove input shaft seal

-Place the special guiding tool (480129) on input shaft（see Fig. 3-2)
-Slide a new seal over the guiding tool (see Fig. 3-3)

Fig. 3-2: Put special tool on input shaft (480129)

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Fig. 3-3: Press the oil seal

-Place the special stamp tool (480130) on input shaft（see Fig. 3-4)
-Hit the special stamp tool with rubber hammer until no further is possible
-Remove special tools and refit transmission in vehicle
-Refill transmission according instruction (see 2.1)

Fig. 3-4: Installing seal by special stamp (480130)

2.6.2.4. Replacing oil seal selector shaft

When:
In case of leakage on oil seal selector shaft
How:
-Drain the oil of the transmission (see changing oil filter)
-Remove the transmission from the car
-Remove lever selector shaft
-Place special tool (480127) over the selector shaft (see Fig. 4-1)

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Fig. 4-1: Put special tool (480127) on shaft

Fig. 4-2: Press and screw tool clockwise

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Fig. 4-3: Rotate screw to remove the seal

Fig. 4-4: Remove the oil seal

-Put some vaseline or grease on the tip of the stamp (480125) (see arrow in Fig. 4-5)
-Take a new seal and slide it over the special stamp (480125) (see Fig. 4-5).
-Place special stamp tool (480125) with seal over the selector shaft and hammer in the
seal until no further possible (see Fig. 4-6 and 4-7).
-Pull out the special stamp tool (480125)

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Fig. 4-5: Slide the seal over the special stamp (480125)

Fig. 4-6: Place special stamp (480125) with seal over the selector shaft

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Fig. 4-7: Hammer down special stamp (480125) with seal till no further is possible

-Remove the stamp while rotating, otherwise there is the possibility the seal comes
back out with the stamp
-Remount the lever selector shaft with new washer (482584) and nut (481329).
-Tighten the nut with 14.5Nm±1.5Nm
-Refit transmission in vehicle
-Refill transmission according instruction (see 2.1)

2.6.2.5. Replacing primary cover

When:
In case of leakage on primary cover
How:
-Drain approx. 1litre of oil out of the transmission (see replacing oil filter)
-The transmission does not need to be removed from the vehicle but may be lowered
together with the engine for easier access
-Loosen the three bolts and clips which are fixing the primary cover to the housing.
-Use a screwdriver to lift out the primary cover. Use some cloth to protect the
transmission from damage (see Fig. 5-1)
-Remove the big O-ring and discard both O-ring and primary cover
-Take a new O-ring and assemble it
-Replace a new primary cover and fix clips and bolts with a torque of 9.5Nm +/- 2.5Nm
-Refill transmission with 1litre of oil

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Fig. 5-1: Remove primary cover from transmission

2.6.2.6. Replacing oil pump

When:
In case the transmission pressure is too low or the driver feel shocks or abnormal
driving behaviour, two main parts can cause this problem, hydraulic unit or oil pump.
Also analyze the P-code and follow actions on specific P-code to replace either
hydraulic unit or pump. In most of cases it is unclear which one the problem causes so
one by one can be replaced and see if the problem is solved.
How:
-Follow the steps to remove the primary cover
-Remove the 6 pump bolts and place special tool (480141) (see Fig. 6-1)
-Pull the sliding part of the tool a few times to lift out the pump (see Fig. 6-2).
-Replace the pump with a new one. Make sure you put 2 new O-rings and 1 plastic
snap ring on the new pump. Do not take out the Belle-ville washer and leave it in its
correct position which is biggest diameter facing the pump (see Fig. 6-3)
-Put the 6 screws back and tighten with (10Nm +/- 1Nm)
-Follow the steps to close back the primary cover, no need to take new primary cover
O-ring and primary cover

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Fig. 6-1: Remove six bolts and place tool (480141)

Fig. 6-2: Pull the tool to lift out pump

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Fig. 6-3: Belle-ville washer

2.6.2.7. Replacing primary ball bearing

When:
In case of worn out primary ball bearing. A worn out primary ball bearing gives a big
noise for which the frequency is dependent on engine speed. This can be easily
checked by driving at a constant speed and shift to sport mode. The engine rpm will go
up and if the noise frequency also goes up, then there is a big possibility that you have
a worn out primary ball bearing.
How:
-Follow the steps to remove the oil pump
-Remove Belle-ville washer
-Mark the position of the primary nut on the shaft (see Fig. 7-1)
-Using an air impact wrench with a torque capacity of +/-300Nm, remove the primary
nut
-Lever out the seal of the primary ball bearing using a small screwdriver (see Fig. 7-2)
-Place the special tool primary plug (480139) (see Fig. 7-3)
-Assemble the bearing puller (480136) underneath the exterior ring of the primary
bearing (see Fig. 7-4)
-Remove primary bearing by tightening the centre bolt of the bearing puller (see Fig. 7-
5)
-Discard primary bearing, clean primary shaft, clean sealant from threads in oil pump
drive shaft and clean oil pump housing (see Fig. 7-6)
-Place a new bearing on the primary shaft and use special stamp tool (480137 +
480126) to put bearing in. Use rubber hammer and hit untill no further possible (see
Fig. 7-7)
-Fit and tighten nut using an air impact wrench for sufficient duration until the marks on
nut and shaft are in line(+/-5°)
-Place back the Belle-ville washer, biggest diameter facing the pump
-Follow the steps of putting back the oil pump

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Fig. 7-1: Mark primary nut and shaft

Fig. 7-2: Lever out seal from primary bearing

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Fig. 7-3: Put special tool on shaft (primary plug 480139)

Fig. 7-4: Assemble bearing puller (480136)

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Fig. 7-5: Tighten centre bolt of bearing puller to lift out bearing

Fig. 7-6: Remove primary bearing

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Fig. 7-7: Fit new primary ball bearing

2.6.2.8. Replacing secondary cover

When:
In case of secondary cover damage or leak.
How:
-The transmission does not need to be removed from the vehicle but may be lowered
together with the engine for easier access
-Loosen the four screws and discard screws
-Take off secondary cover, remove the small and bigger O-ring and the center sealing
ring
-In case of damaged cover, take a new secondary cover
-Replace new O-rings and sealing ring
-Remove the glue (glue from the sealant screws) gently from the transmission housing
-Tighten the secondary cover with 4 new screws, torque 9.5Nm +/- 0.95Nm

Fig.1：Take off secondary cover bolt

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