Note. To perform the procedures described below, you will need a special type throne jack. Performing work without its use is associated with an increased risk of injury due to the significant weight of the assembly.
Removing
1. Drive the car with the rear wheels onto the overpass, cock the parking brake and block the rear wheels with wedges.
2. Jack up the front of the car and place it on jack stands.
3. Disconnect the negative cable from the battery.
4. Remove the front seats and center console.
5. Give fixing screws and remove overlays of thresholds. Remove the front mat.
6. Remove the handles from the shift levers and transfer case modes. Give screws of fastening of the panel of a floor. Remove the floor panel with rubber protective covers and remove it from the vehicle.
7. Give the fixing bolts and remove from the transmission the casing of the gearshift drive assembly with the manual transmission control lever.
8. Release the parking brake, remove the clamp and remove the pin that secures the drive cable to the parking brake control lever. Loosen the mounting nuts, release the cable sheath from the bracket and push the cable through the floor panel.
9. Remove the drain plug and drain the gear oil from the gearbox housing. After the oil flows out, lubricate the threads with sealant and screw the plug into place.
10. Mark the position of the front and rear cardan shafts relative to each other, as well as their position relative to the flange of the final drive gear (see accompanying illustration), transfer case flange and parking brake drum.
11. Give bolts and nuts and remove cardan shafts from the car.
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. Give the bracket mounting bolts and remove the transfer case shift lever from the transmission housing.
14. Disconnect the ventilation hoses and electrical wiring from the transfer case and transmission housings.
15. Place a trolley jack under the transfer case and secure the assembly to it with a sling or chain.
16. Give bolts of fastening of a distributing box to transmission and remove a box from the car.
Note. The weight of the transfer case is about 50 kg, and therefore the compilers of this manual strongly recommend the use of a trolley jack to remove it.
17. Give fixing bolts and remove the slave cylinder from the clutch housing. Secure the cylinder to the side by tying it with wire to the chassis member.
18. Give a nut with a bolt and remove rubber pillows from a basic arm of a suspension bracket of system of release of the fulfilled gases
19. Disconnect the electrical wiring from the starter, give the mounting bolts and remove the starter from the car.
20. Where applicable, remove the PTO assembly from the transmission and secure it out of the way.
21. Give bolts of fastening of a dome of coupling to the engine, remove reinforcing brackets and a back guard of the engine.
22. Place a special jack under the gearbox housing and tie the transmission to it with a chain.
23. Support the transmission with a jack, give the nuts and bolts securing the cross beam to the chassis frame and transmission supports. Remove the cross member from the vehicle.
24. Carefully lower the jack, making sure that the wires and hoses connected to the engine are not taut, and carefully remove the transmission from under the car.
Note. In the process of removing the transmission, do not allow it to hang with its entire weight on the clutch driven disk in order to avoid failure of the latter.
25. Check up serviceability of functioning of coupling.
Installation
Appearance of the gearbox with related components
1 - clutch dome; 2 - a casing of a drive of a gear change (selector); 3 - top cover; 4 - extension casing; 5 - off lever; 6 - PTO cover; 7 - tube; 8 - support
Installation is in the reverse order.
1. Apply a moderate amount of grease to the splines of the input shaft of the manual transmission, lubricate the contact surface of the guide sleeve with oil.
2. Check the cleanliness of the mating surfaces of the engine rear shield and clutch dome. Lubricate the flange of the latter with Loctite 587 sealant or equivalent.
3. Raise the transmission with a jack and align it with the engine, making sure that the mating surfaces of the clutch dome and the engine rear shield are parallel to each other.
4. With the transmission in gear, rotate the output shaft to align the primary pin splines with the mating splines in the hub of the clutch disc.
5. Press the transmission against the engine, tighten all the bolts to the required force and connect the electrical wiring and ventilation hoses to their original position.
6. Reinstall the clutch slave cylinder, if necessary, bleed the hydraulic system.
7. Apply a pad of sealant to the starter mounting flange and set the latter to the distance.
8. Having followed the alignment of the landing marks, reinstall the cardan shafts.
9. Connect and adjust the parking brake cable.
10. Install the shift housing assembly with shift lever. Do not forget to replace the gasket and make sure that the long fixing bolts are screwed into the points shown in the accompanying illustration (A).
11. Fill the transmission with the required amount of oil of the required grade. Lubricate the threads of the filler plug with sealant and tighten it firmly.