Contents: External details ↧ Transfer case tailpiece into pump… ↧ Cleaning and checking the condition… ↧
1. Remove the transfer case.
2. Clean the transfer case.
External details
3. Unscrew the front flange nut, remove the washer, rubber seal and front flange.
4. Remove the indicator lamp switch and sealing ring.
5. Remove the speedometer sensor and oil seal.
6. Loosen the disc valve screw, remove the sealing ring, spring and plunger of the disc valve.
Transfer case tailpiece into pump body
7. Loosen the bolts and remove the transfer case tailpiece.
8. Remove the bearing retaining ring from the transfer case shaft.
9. Unscrew the pump body holder bolts.
10. Remove the holder.
11. Remove the retaining rings and speedometer wheel from the transfer case shaft.
12. Unscrew the bolts securing the two halves of the crankcase. It should be noted that the two longer bolts enter the holes in which the guide pins are also installed.
13. Separate the parts of the gearbox housing by inserting a screwdriver between the lugs in the housing.
Caution! Separate the crankcase sections by inserting the tool only between the lugs. Take care not to damage the oil pump located at the rear of the transfer plug crankcase.
14. Remove the oil pump, oil receiver pipe, sealing ring and oil receiver filter from the rear of the crankcase.
15. Remove the transfer case engagement fork spring.
16. Remove the snap ring from the front transfer case shaft.
17. Remove the primary shaft, chain and driven sprocket from the front of the crankcase. The transfer case mode engagement fork and fork guide are removed together with the primary shaft.
18. Remove the retaining ring from the gearbox input shaft.
19. Remove the synchronizer unit. Remove the drive sprocket from the input shaft.
20. Remove the transfer case shift fork and the clutch hub. Remove the linkage together with the shaft and planetary carrier. To remove the fork, turn the linkage with the shaft.
21. Loosen the gear shift lever nut, remove the washer, lever, plastic washer and sealing ring from the front section of the transfer case housing.
22. Unscrew the bolts of the gearbox input shaft bearing housing and remove the bearing housing.
23. Remove the bearing retaining ring.
24. Remove the planetary gear carrier and pinion gear by knocking them out with a soft-faced hammer.
25. Remove the retaining ring holding the synchronizer locking ring.
26. Use a puller to press the bearing off the drive shaft. Remove the carrier retaining ring and thrust washer.
27. Using an impact puller, press out the drive sprocket needle bearing.
28. Using an impact puller, press all needle bearings off the drive shaft.
29. Remove the first retaining ring of the transfer case secondary shaft,
30. Remove the front secondary shaft seal from the front section of the transfer case housing.
31. Using a puller, press the front secondary shaft out of the front section of the transfer case housing.
32. Remove the seal from the transfer case tailpiece.
33. Remove the oil seal from the front bearing retainer.
C 34. Remove the second bearing at the front of the secondary shaft. Use an impact puller to press all the needle bearings off the shaft.
35. Remove the bearing from the holder.
36. Remove the magnet from the front section of the transfer case housing.
37. Mark the position of the hub and synchronizer sleeve to ensure these parts are positioned correctly during assembly.
38. Remove the retaining ring.
39. Remove the synchronizer locking ring.
40. Remove the synchronizer hub.
41. Remove the screws from the oil pump.
42. Remove all gears.
Cleaning and checking the condition of parts
43. Clean and wash all parts of the internal structure of the box. Blow them with compressed air. Clean the oil supply channels especially thoroughly.
44. Check the wear of bearings, thrust washers, teeth and splines on gears and shafts, check for cracks, corrosion, and wear.
45. Carefully check the condition of the synchronizer parts - the locking rings, clutch and hub. Check the condition of the drive chain.
46. Check the condition of the separating surfaces on the transfer case housing sections.
47. Check the condition of the oil pump gears. If they are worn, replace the pump assembly.
48. Assembly is carried out in reverse order, taking into account the following.
All bearings are pressed on using mandrels of suitable diameter.
The rear crankcase section needle bearing is pressed in so that the edge of the bearing is flush with the boss on the crankcase section.
Press the planetary mechanism into the ring gear using a soft-faced hammer.
Lubricate the split surface of the primary shaft bearing holder with RTV sealant.
Lubricate the bearing housing and gearbox housing tail bolts with a fixing compound.
Please note that during assembly, the sealing ring of the oil pump receiver must not be damaged, otherwise the pump will fail.