Note. You will need the following special tools to complete the procedures below: 30mm replacement socket (for removing the front drive flange); head 32 mm (for removing the rear drive flange); dial gauge, puller kit, press with backing plates and head type TORX T45 (to disassemble the box); press with support plates and T45 head (to assemble the box).
Removing
1. Drive the car with the rear wheels onto the overpass, set the parking brake firmly and block the rear wheels with wedges.
2. Jack up the front of the car and place it on jack stands.
3. Turn out a stopper and merge oil from a distributing box. Lubricate the threads of the drain plug with sealant, screw in and tighten the plug firmly.
4. Mark the position of the front and rear cardan shafts relative to each other, as well as their position relative to the main gear drive flange, transfer case flange and parking brake drum.
5. Give bolts and nuts and remove cardan shafts from the car.
6. If the transfer box is subject to disassembly or the oil seal needs to be replaced, re-translate the box mode switch lever to the 4H position and, using a 30 mm socket, release the front drive flange mounting nut.
7. If necessary, remove the front drive flange using a puller. Remove the seal from the transfer box (use a puller or sliding hammer).
8. Using a 32 mm socket, loosen the rear drive flange mounting nut to the box, mark the position of the flange in relation to the parking brake drum.
9. Release the parking brake, remove the drum of its mechanism, then use a puller to remove the rear drive flange.
10. Give bolts of fastening of a back board of the parking brake mechanism and remove assembly of a brake from a distributing box. Secure the assembly to the side to prevent the drive cable from being pulled out.
11. If necessary, remove the rear drive flange oil seal from the transfer case housing (use a puller or sliding hammer).
12. Bend back the rubber protective cover, unscrew the nut that secures the shift rod to the transfer case control lever, remove the washer and spacer. Disconnect the shift rod from the control lever.
13. Disconnect the ventilation hose, disconnect the electrical connectors and release the electrical wiring from the mounting clamps on the transfer case.
14. Place a jack under the transmission, support the latter with it, taking its weight along with the weight of the transfer case.
15. Loosen the bolts securing the transverse beam of the transmission support to the vehicle chassis frame and carefully lower the jack so that it is possible to unscrew the upper bolts securing the transfer case to the transmission.
16. Give all fixing screws except for the bottom ones.
17. Raise the jack brought under the transmission and screw in the transverse beam mounting bolts.
18. Place a trolley jack under the transfer case and secure the latter to it with a chain or sling.
19. Give the remaining mounting bolts and remove the transfer case from under the car (the appearance of the transfer box assembly removed from the car is shown in the accompanying illustration).
1 - front output shaft; 2 - stuffing box; 3 - central crankcase; 4 - rear crankcase; 5 - sensor-switch 4WD (all-wheel drive mode); 6 - front crankcase; 7 - input shaft; 8 - bearing holder
Note. The transfer case weighs approximately 50 kg and attempting to remove it without using a trolley jack can result in personal injury and component damage.
Installation
Installation is in the reverse order.
1. If necessary, lubricate the oil seal lips of the drive flanges with a lithium-based multipurpose grease and install the oil seals in the transfer case.
2. Tighten with the required effort the mounting bolts of the transfer case.
3. Tighten with the demanded effort bolts of a back guard of the parking brake mechanism. Apply the parking brake and tighten the flange nuts to the required torque.
4. Install cardan shafts (in accordance with the marks made during the dismantling process).
5. Fill the transfer case with the required amount of oil of the required grade (see tables of sizes and adjustments at the end of the guide).
6. Carry out road tests of the car, checking the serviceability of the transfer case. Check the oil level in the box, top up if necessary.