798646e1

9.3.4. Assembly

Installation is made as it should be, the return to a dismantle order.

 PERFORMANCE ORDER

  1. By means of a suitable mandrel put epiploons in back and central cases and the holder of the bearing of an entrance shaft aflush with a surface of components. Grease sponges of epiploons with universal lubricant on a lithium basis.
  2. Oil all components pure the required grade.
  3. Put on gear rings, springs and remote rings an intermediate shaft. track that springs were established by the concave party to a gear wheel. By means of a press install bearings of an intermediate shaft.
  1. Establish a remote ring on a forward part of an intermediate shaft and measure a side gap between a lock ring and a flute (see an accompanying illustration). Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management) and pick up a new lock ring of the required thickness.
  1. By means of a press dress on the conducted shaft the forward bearing (the party equipped with the screen to a flange of the conducted shaft).
  2. Establish a remote ring on the conducted shaft and measure a side gap between a lock ring and a flute. Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management) and pick up a new lock ring of the required thickness.
  3. Oil the forward bearing of the conducted shaft of the required grade and establish on a shaft it the holder and a forward driving asterisk. Oil the roller bearing and, rotating an asterisk, dress the bearing on a shaft.
  4. Install the synchronizer coupling, the sliding keys and a spring on a forward driving asterisk. Track that the coupling was installed by bore from an asterisk, keys - the short ends. Make sure of correctness of gearing of keys with a spring.
  5. Combine grooves of blocking synchronizer ring with keys and dress a ring on a driving asterisk. By means of a press establish a gear wheel of coupling and the back bearing on the conducted shaft. Track that the bearing was turned by the party equipped with the screen to a coupling gear wheel.
  6. By means of a press with basic plates dress bearings on forward output and entrance shaft. Track that the external lock ring of the bearing of an entrance shaft was turned from a gear wheel aside.
  7. Establish a remote ring on an entrance shaft and measure a side gap between a lock ring and a flute. Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management) and pick up a new lock ring of the required thickness.
  8. Establish an epiploon of the internal lever of switching in a forward case and grease epiploon sponges.
  9. Install the internal lever of switching in a forward case. Establish a finger, track that flat segments of the lever were combined with it, then strongly tighten a fixing nut.
  1. Begin to knock an entrance shaft in a forward case by means of the hammer with soft brisk. Grease the interfaced surface of the holder of the bearing and a carving of fixing bolts with Loctite 515 sealant (or equivalent to it). Tighten bolts with the required effort (And = 16 ÷ 21 Nanometers; In = 19 ÷ 24 Nanometers - see an accompanying illustration). Grease the roller bearing with lubricant of the required grade and dress it on an entrance shaft.
  1. Begin to knock an intermediate shaft in a forward case the hammer with soft brisk.
  2. Establish a clamp plunger in a forward case. Install rods of switching and a fork on the coupling of switching raising/lowering transfers and insert assembly into a forward case.
  3. Grease with sealant of a cap and establish the fixing balls and springs. Grease with sealant the alarm sensor switch 4WD and, on models with AT, the sensor switch of permission of start.
  4. Establish a spring and the plug in a fork of switching 2-4, having tracked that the plug was oriented as before. Establish a new lock ring.
  5. Install a fork of switching of the modes 2-4 in the coupling of the synchronizer and dress a driving chain on driving asterisks of the conducted and output shaft.
  6. Exactly establish assemblies of the conducted and output shaft in the central case and by means of the hammer with soft brisk begin to knock shaft serially before full landing of bearings. In case of need for landing of the bearing establish the holder and tighten his bolts. Tighten bolts of holders of bearings with the required effort.
  7. Grease the roller bearing and install it and a gear wheel of the lowering transfer on the conducted shaft. By means of a suitable mandrel put on the conducted shaft a nave raising/lowering transfers. The nave has to be turned by flutes towards a gear wheel of the lowering transfer. Establish a lock ring.
  8. By means of the probe of lezviyny type measure a gap between a gear wheel of the lowering transfer and the nave which is raising/lowering transfers. If air pump of an axial side play goes beyond admissible limits (see size tables and adjustments at the end of the Management), remove a gear wheel and a nave and replace defective components.
  1. Check the size of an axial side play of an intermediate shaft (see an accompanying illustration):
    1. Press the planeness measuring instrument to an external holder of the back bearing of an intermediate shaft and measure a gap between interfaced a surface of a forward case and a planeness measuring instrument edge (see an illustration).
    2. For determination of the required thickness of an adjusting washer compare results of measurements to the standard data provided in the table:

Size of a gap, mm

Thickness of an adjusting washer, mm

40.6 ÷ 40.5

The washer is not required

40.5 ÷ 40.4

0.1

40.4 ÷ 40.3

0.2

40.3 ÷ 40.2

0.3

40.2 ÷ 40.1

0.4

40.1 ÷ 40.0

0.5

40.0 ÷ 39.9

0.6

    1. In case of need install an adjusting washer of the required thickness on the bearing of an intermediate shaft.
  1. Grease with Loctite 515 sealant (or equivalent) to it the interfaced surface of a forward case and establish assembly of the central case, directing a fork of switching to a rod of switching and watching correctness of an arrangement of shaft.
  2. Establish a lock ring of a rod of switching 2-4, a maslostok and a gear wheel of the drive of a speedometer.
  3. Grease internal components of the transfer case with lubricant of the required grade.
  4. Impose Loctite 515 sealant (or equivalent to it) on the interfaced surface and establish a back case. Tighten fixing bolts in a diagonal order with the required effort and establish assembly of the drive of a speedometer.
  5. Install the transfer case on the car and tighten fixing nuts of driving flanges with the required effort.