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9.3.1. Removal and installation

The following special tools will be necessary for implementation of the procedures described below: a replaceable face head on 30 mm (for removal of a forward driving flange); a head on 32 mm (for removal of a back driving flange); the dial measuring instrument, a stripper set, a press with basic plates and a head like TORX T45 (for dismantling of a box); a press with basic plates and T45 head (for assembly of a box).

Removal

 PERFORMANCE ORDER

  1. Tire out the car with back wheels on a platform, strongly cock the parking brake and block back wheels wedges.
  2. Car front also establish to Poddomkratta it on props.
  3. Turn out a stopper and merge oil from the transfer case. Grease a carving of a drain stopper with sealant, screw and strongly tighten a stopper.
  4. Mark position of forward and back driveshafts from each other, and also situation them concerning a flange of the leading gear wheel of the main transfer, a flange of the transfer case and a drum parking a brake.
  5. Give bolts and nuts and remove driveshafts from the car.
  6. If the transfer case is subject to dismantling or demands replacement an epiploon peperevedit the lever of switching of the modes of a box in situation 4H and by means of a head on 30 mm give a nut of fastening of a forward driving flange.
  7. In case of need remove a forward driving flange by means of a stripper. Take an epiploon from the transfer case (use a stripper or the hammer with sliding brisk).
  8. By means of a head on 32 mm give a fastening nut to a box of a back driving flange, mark the provision of a flange in relation to a drum of the parking brake.
  9. Release the parking brake, remove a drum of its mechanism, then by means of a stripper remove a back driving flange.
  10. Give bolts of fastening of a back board of the mechanism of the parking brake and remove assembly of a brake from the transfer case. In order to avoid a pulling of a driving cable fix assembly aside.
  11. In case of need take an epiploon of a back driving flange from a case of the transfer case (use a stripper or the hammer with sliding brisk).
  12. Unbend a rubber protective cover back, turn off a nut of fastening of a rod of switching to a control lever of the transfer case, remove a washer and the remote plug. Disconnect a switching rod from a control lever.
  13. Disconnect a ventilating hose, disunite electric sockets and release an electrical wiring from fixing collars on the transfer case.
  14. Get a jack under transmission, prop up it the last, having accepted its weight together with the weight of the transfer case.
  15. Give bolts of fastening of a cross beam of a support of transmission to a frame of the chassis of the car and carefully lower a jack so that the possibility of a reversing of the top bolts of fastening of the transfer case to transmission appeared.
  16. Give all fixing screws except for lower.
  17. Lift the jack got under transmission and screw bolts of fastening of a cross beam.
  18. Get a cart jack under the transfer case and fix on it the last by a chain or a sling.
  19. Give the remained fixing bolts and take the transfer case from under the car (appearance of the assembly of the transfer case removed from the car is shown on an accompanying illustration).
1 — a forward output shaft
2 — an epiploon
3 — the central case
4 — a back case
5 — the sensor switch 4WD (the all-wheel drive mode)
6 — a forward case
7 — an entrance shaft
8 — the holder of the bearing

The weight of the transfer case makes about 50 kg and therefore attempts of its removal without application of a cart jack are fraught with getting injured and damage of components.

Installation

Installation is made upside-down.

 PERFORMANCE ORDER

  1. In case of need grease sponges of epiploons of driving flanges with universal lubricant on a lithium basis and install epiploons in the transfer case.
  2. Tighten fixing bolts of the transfer case with the required effort.
  3. Tighten bolts of a back guard of the mechanism of the parking brake with the required effort. Cock the parking brake and tighten with the required effort of a nut of fastening of flanges.
  4. Install driveshafts (according to the tags made in the course of dismantle).
  5. Fill in in the transfer case necessary amount of oil of the required grade (see size tables and adjustments at the end of the Management).
  6. Carry out trial runs of the car, checking serviceability of functioning of the transfer case. Check oil level in a box, in case of need make addition.