2. Clean the transfer case.
Exterior details
3. Remove the front flange nut, washer, rubber seal and front flange.
4. Remove the switch of a control lamp and a sealing ring.
5. Remove the speedometer sensor and oil seal.
6. Loosen the poppet screw, remove the o-ring, spring, and poppet valve plug.
Transfer box shank to the pump housing
7. Turn away bolts and remove a shaft of a distributing box.
8. Remove the bearing circlip from the transfer case shaft.
9. Turn away bolts of the holder of the case of the pump.
10. Remove the holder.
11. Remove the retaining rings and the speedometer wheel from the transfer case shaft.
12. Turn out bolts of fastening of two halves of a crankcase. It should be noted that two bolts with a longer length enter the holes into which the guide pins are also installed.
13. Separate the parts of the box crankcase by inserting a screwdriver between the lugs in the crankcase.
Attention! Separate the crankcase sections by inserting the tool only between the lugs. Take care not to damage the oil pump located at the rear of the transfer plug housing.
14. Remove the oil pump, the oil receiver pipe of the pump, the O-ring and the oil receiver filter at the rear of the crankcase.
15. Remove the transfer case fork spring.
16. Remove the circlip from the front shaft of the transfer case.
17. Remove the input shaft of the box, chain and driven sprocket from the front of the crankcase. The transfer case selector fork and the fork guide are removed together with the input shaft.
18. Remove the snap ring from the input shaft of the box.
19. Remove the synchronizer assembly. Remove the drive sprocket from the input shaft.
20. Remove the transfer case shift fork and clutch hub. Remove the yoke together with the shaft and planetary carrier. To remove the fork, turn the link with the roller.
21.Unscrew the gear change lever nut, remove the washer, lever, plastic washer and O-ring in the front section of the transfer case housing.
22. Turn away bolts of the case of the bearing of a leading shaft of a box and remove the case of the bearing.
23. Remove the bearing circlip.
24. Remove the planetary carrier and drive gear by knocking them out with a soft-faced hammer.
25. Remove the circlip holding the synchronizer blocking ring.
26. Press the bearing off the drive shaft with a puller. Remove carrier retaining ring and thrust washer.
27. Using an impact puller, press out the needle bearing of the drive sprocket.
28. Using an impact puller, press all needle bearings off the input shaft.
29. Remove the first circlip of the output shaft of the transfer case,
30. Get a forward epiploon of a secondary shaft from forward section of a case of a distributing box.
31. Using a puller, press the front secondary shaft out of the front section of the transfer case housing.
32. Remove the oil seal from the transfer case shank.
33. Remove the oil seal from the front bearing holder.
C 34. Remove the second bearing at the front of the output shaft. Using an impact puller, press all needle bearings off the shaft.
35. Remove the bearing from the holder.
36. Remove the magnet from the front section of the transfer case housing.
37. Mark the position of the hub and synchronizer sleeve to set these parts in place during assembly.
38. Remove the circlip.
39. Remove the synchronizer blocking ring.
40. Get a nave of the synchronizer.
41. Turn out screws from the oil pump.
42. Remove all gears.
Cleaning and checking the condition of parts
43. Clean and rinse all parts of the internal structure of the box. Blow them out with compressed air. Clean the oil supply channels especially carefully.
44. Check the wear of bearings, thrust washers, teeth and splines on gears and shafts, check for cracks, corrosion, wear.
45. Carefully check the condition of the synchronizer parts - blocking rings, clutch and hub. Check the condition of the drive circuit.
46. Check up a condition of demountable planes on sections of a case of a distributing box.
47. Check the condition of the oil pump gears. If they are found to be worn, replace the pump assembly.
48. Assembly is carried out in the reverse order, taking into account the following.
All bearings are pressed on with mandrels of suitable diameter.
The rear crankcase needle bearing is pressed in so that the edge of the bearing is flush with the boss on the crankcase section.
Press the planetary mechanism into the ring gear with soft-faced hammer blows.
Lubricate the split plane of the input shaft bearing holder with RTV sealant.
Lubricate the bolts of the bearing housings and the shank of the crankcase with a fixing compound.
Please note that during assembly, damage to the sealing ring of the oil receiver of the oil pump is not allowed, otherwise the pump will fail.