Disassembly and assembly

Disassembly. Flush the transfer case and drain the oil.

Mount the transfer case on a stand for dismantling, install the locking tool and loosen the nuts securing the flanges on the input shaft and on the front and rear axle drive shafts. Having unscrewed the nut of the flange of the rear axle drive shaft, remove the flange with the washer.

Having unscrewed nuts of fastening of a back cover 31 (see fig. 3-28), remove the cover assembly with the rear axle drive shaft.

Install the locking device on the driveshaft flange, engage any gear and unscrew the nuts securing the rear bearings of the driveshaft and countershaft. Then remove the mounting rings.

After unscrewing the four nuts securing the inspection hatch cover, remove the washers and the cover.

Install the locking device and, having unscrewed the nuts securing the flanges of the front axle drive shaft and the drive shaft, remove the flanges 12.

Remove bolt 24 (see fig. 3-29) fastenings of the shift fork and carefully, closing the latch socket with your finger, remove the stem 12, the fork 17, the distance sleeve 18, the latch parts. Remove cover 4.

Remove the rod 15, unscrew the fastening nuts and remove the cover of the front bearing of the input shaft. Then remove the speedometer drive housing with driven gear 15 (see fig. 3-28).

Having unscrewed two nuts 14 (see fig. 3-32), remove the bracket with control lever 4 for the transfer case. Then remove the front axle drive housing with lever and differential lock clutch.


Remove front cover 4 (pic. 3-34) together with the differential, then remove the differential bearing set ring and remove the bearing assembly with differential from the front cover.

Remove the adjusting rings from the rear bearings of the drive and intermediate shafts and remove both drive and intermediate shafts from the transfer case housing.

Clamping the drive shaft in a vise, remove the thrust ring and rear bearing 11 (pic. 3-35), using a universal puller. Remove low gear 9 with bushing 10, gearshift clutch 8, clutch hub 7, high gear 6 from the drive shaft.










Disassemble the differential, for which:

• remove retaining ring 1 (pic. 3-36) and spring washer 2 front bearing;
• remove the rear and front bearings from the differential housing (pic. 3-37), using the universal puller and stop 67.7853-9559;
• unscrew the bolts of the differential driven gear, mark the risks on the differential housings with their relative position relative to each other and disconnect the housing;
• remove the differential driven gear;
• remove retaining rings 8 (see fig. 3-36) and spring washer 14, then press out the axis of the satellites and remove the satellites and gears of the drive axles with support washers.

Press out from the front cover 4 (see fig. 3-34) front bearing outer race 15 (see fig. 3-35) intermediate shaft 14.


Press bearing 13 and bearing inner race 15 off intermediate shaft 14 using universal puller and stop 67.7853-9559.

Disassemble the rear cover 31 (see fig. 3-28), For what:

• remove the adjusting ring and press bearing 36 with the rear axle drive shaft out of the cover;
• remove the oil deflector and thrust ring (in the presence of).

Clamping the input shaft in a vise, press the bearing 36 from the rear axle drive shaft using a universal puller and stop 67.7853-9559.

Disassemble the front axle drive housing, for which put the differential lock lever in position "unlocked" and remove the clutch 5 of the differential lock.

Loosen the cover nuts 7 (see fig. 3-29) front axle drive housing, remove the cover with differential lock lever 11, remove the spring and lock ball 19.

Unscrew the bolt securing the fork 1 of the differential lock, remove the stem 6 and the fork 1, remove the cover 4 from the stem.

Remove the adjusting ring and press bearing 8 out of the crankcase (see fig. 3-28) with the shaft 11 of the front axle drive, remove the oil deflector 9 and the thrust ring (in the presence of).

Clamping the shaft 11 of the front axle drive in a vise, press the bearing 8 off the shaft.

Remove the o-ring from the front axle drive housing and press out worn or damaged oil seals from the front axle drive housing, front bearing cap and rear cover. Loosen nuts 6 (see fig. 3-33) from the axles of the suspension cushion and remove the brackets 3 as an assembly.

Disassemble the cover of the front axle drive housing, for which remove the lock washer 8 (see fig. 3-29), knock out the axle 10 and remove the lever 11 of the differential lock from the cover 7, remove the bushings 9 of the axle. Turn away the switch 22 of a control lamp of blocking of differential.


Disassemble the mechanism of the transfer case control lever, for which unscrew the nut 6 (see fig. 3-32), remove axle 1 and remove bushings 2, spacer bushing 3 and control lever 4. Unscrew nut 19, remove control lever fork 13 from control lever bracket 16 and remove bushings 2.

The assembly of the transfer case is carried out in the reverse order of disassembly, taking into account the following:

• assemble the center differential by aligning the marks on its housings so as not to disturb the balance of this unit;
• install the spring washer on the axis of the satellites from the side of the blind hole on the end of the axis;
• the axial clearance of each axle drive gear should be 0-0.10 mm, and the moment of resistance to rotation of the gears should not exceed 14.7 Nm (1.5 kgcm). With increased clearance, replace the support washers with others of greater thickness; if the specified clearance cannot be obtained when installing the support washers of the greatest thickness, replace the gears with new ones due to their excessive wear;
• drive and intermediate shafts are installed in the transfer case at the same time (see fig. 3-38);
• pressing the bearings onto the differential housing is carried out with a mandrel 67.7853-9558 (see fig. 3-39);

• lubricate the working surfaces of the seals with Litol-24 grease before installation in the covers and crankcases;
• before assembly, clean the surfaces of the rear cover, the bearing cap of the input shaft and the speedometer drive housing from the remnants of the old gasket and apply the PS-1 liquid gasket along the perimeter of the surfaces in contact with the transfer case crankcase with a continuous roller with a diameter of 1... 2 mm
• when crimping the nuts of the transfer box shafts, use a blunt chisel (see fig. 3-40).

After assembly, fill the transfer case with oil up to the lower edge of the filler hole.