Oil seal and axle shafts
Removal and installation
Removal
1. Remove the front drive shafts. See chapter «Front axle and suspension».
2. Remove the differential seals (1) using a suitable tool.
Attention. Do not damage the gearbox and clutch housings.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
- Press in the seals (1) in the clutch and gearbox housing using a drift (A) (special tool: KV3B100300).
B. From the gearbox side; C. Clutch housing side
Size «L1»: 1.2-1.8 mm.
Size «L2»: 2.7-3.3 mm.
Attention:
- Do not reuse the seal.
- Do not tilt the oil seal when pressing.
- Do not damage the gearbox and clutch housings.
- After installation, check the oil level for leaks. See above.
Lever mechanism for controlling the gearbox. 1. Bracket; 2. Gear shift cable; 3. Gear selector; 4. Shift lever; 5. Self-tapping bolt; 6. Cable fastening bracket; 7. Gear selection cable; 8. Rubber bushing; 9. Gear shift mechanism assembly; 10. Gear shift lever; 11. Gear shift knob.
Removal and installation
Removal
1. Remove the air cleaner housing and air duct (inlet) or air ducts See Chapter «Mechanical part of the engine».
2. Remove the battery.
3. Disconnect the connectors (A) and then remove the bracket (1).
4. By squeezing the gear selector cable clamp in the direction of the arrow as shown in the figure, disconnect the gear selector cable from the gear selector lever.
5. Squeeze the shift cable clamps in the direction of the arrow as shown in the illustration, and disconnect the shift cable from the shift lever.
6. By pulling the selector cable clamps in the direction of the arrow as shown in the figure, remove the selector cable from the mounting bracket.
7. By pulling the shift cable clamps in the direction of the arrow as shown in the figure, remove the shift cable from the mounting bracket.
8. Remove the gear shift knob.
Note. Pull the gear shift knob and remove it.
9. Remove the console trim assembly and center console assembly. See chapter «Interior and exterior equipment».
10. Move the gear shift lever to neutral.
11. Squeeze the selector cable clips in the direction of the arrow as shown in the illustration, and disconnect the selector cable from the shift mechanism assembly.
12. Squeeze the shift cable clamps in the direction of the arrow as shown in the illustration, and disconnect the shift cable from the shift assembly.
13. Pull the selector cable retainers in the direction of the arrow as shown in the illustration to remove the selector cable from the shift assembly.
14. Pull the shift cable retainers in the direction of the arrow as shown in the illustration to remove the shift cable from the shift assembly.
15. Remove the gear shift assembly.
16. Remove the heat shield.
17. Remove the bracket.
18. Take out the rubber bushing and remove the shift cable and gear selection cable from the vehicle.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
- Move the gear shift lever to neutral.
- Connect each cable securely to the selector lever and shift lever, and install each cable securely to the mounting bracket.
- Connect each cable securely to the shift assembly.
- Make sure that the protrusions of the rubber bushing are in contact with the floor surface.
- Place the handle on the gear shift lever, observing the installation direction.
Attention. Do not reuse the gear shift knob.
- There is no preliminary threading for the self-tapping bolt in the new clutch housing. Threading occurs when a self-tapping bolt is screwed into the clutch housing.
Attention. Do not reuse the self-tapping bolt.
- Connect the gear selection cable (from the side of the gear shift mechanism assembly) as follows:
1. Pull the selector cable clamps in the direction of the arrow as shown in the illustration to connect the selector cable to the shift assembly.
2. Slide the lock (1) selector cable in the direction of the arrow as shown in the figure and pull the stopper (2) gear selection cable.
3. Place the selector cable end onto the shift pin assembly.
4. Insert the lever locking pin (1) or rod (diameter 3 mm) into the gear shift mechanism assembly.
Attention. Make fine adjustments to the gear selection cable without using a lever locking pin or rod (diameter 3 mm) it is forbidden.
Note. The lever locking pin is not included in the gearshift kit. Therefore, if the mechanism is not replaced, stock up on a rod (diameter 3 mm).
5. Make sure that the gear shift lever does not move in the direction of gear selection. If he moves, perform step 3 again.
6. Move the gear lever to the 4th gear position.
7. Pressing in the stopper (1) gear selection cable, slide the lock (2) selector cable in the direction of the arrow.
8. Insert the lever locking pin or rod (diameter 3 mm) from the gear shift mechanism assembly.
9. Move the gear shift lever to all positions and make sure that it does not jam. Otherwise, repeat step 3.
Check after installation
- Make sure that when shifting the lever towards 1st/2nd gears and towards 5th/6th gears, the shift lever smoothly returns to the neutral position.
- Make sure that when changing gears the lever does not jam and is locked in each position.
Breather hose
Removal and installation
Removal
When removing, refer to the illustration on the next page.
Attention. When removing the breather hose, hold the two-way coupling securely.
Installation
- Refer to the illustration on the next page for installation.
- When connecting the breather hose to the two-way coupling, turn the paint mark toward the front of the vehicle.
- When connecting the breather hose to the two-way coupling, push it until it rests against the transmission housing.
- When connecting the breather hose to the air cleaner body, make sure the clamp is fully inserted.
Attention. Make sure that the breather hose does not have any pinched or narrowed areas that may have been caused by bending or folding during installation.
Breather hose. Removal and installation 1. Breather hose; 2. Gearbox assembly; 3. Two-way coupling; 4. Air cleaner housing.