Dismantling
1. Disconnect "negative" battery terminal.
2. Remove the rear cross member.
FRONT SUSPENSION, REPAIR WORKS, Front subframe.
3. Remove a reception pipe of system of release.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, volume 1.8, REPAIR WORKS, Downpipe.
4. Drain the oil from the transfer case.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
5. Drain the gearbox oil.
MANUAL TRANSMISSION - PG1, ADJUSTMENTS, Transmission oil change in the box.
6. Turn away 3 bolts of fastening of the right dirt-protective panel and remove the panel.
7. Install tool LRT-54-026 on the drive shaft inner joint. Using the lever, release the drive shaft from the transfer case.
8. With the help of a partner, move the hub outward and remove the drive shaft from the transfer case.
CAUTION: When removing the drive shaft, be careful not to damage the oil seal.
9. Remove and discard the drive shaft retaining ring.
10. For ease of reassembly, mark the position on the front propeller shaft.
11. Raise one rear wheel so that the driveshaft can be rotated to access the bolts.
12. Turn away 6 nuts and remove bolts of fastening of a cardan shaft to a leading flange of a distributing box.
13. Remove the propeller shaft from the transfer box drive flange and tie it aside.
CAUTION: Care must be taken when removing the three-roller joint from the transfer case. In order not to damage the cover, it must not be fully stretched, the hinge body must be protected from shock.
14. Turn away 3 nuts of fastening of a damper to a case of a shaft of a drive of the back bridge.
15. Remove the damper.
16. Disconnect the breather hose from the transfer case housing.
17. Install a container to collect escaping coolant.
18. Loosen the clamp and disconnect the cooling system hoses from the transfer case.
19. Turn away a bolt of fastening of the bottom crossbar to an arm on the pallet.
20. Remove the lower cross member of the engine mount.
21. Turn away 3 bolts of fastening of an arm of the lower crossbar to the pallet and remove an arm.
22. Turn away the top bolt of fastening of an arm of a distributing box to the block of cylinders.
23. Turn out 5 bolts of fastening of an arm to a distributing box.
24. Turn out 3 bolts of fastening of an arm of a distributing box to the pallet and remove an arm.
25. Turn away 4 bolts of fastening of a distributing box.
26. With the help of a partner, separate the transfer case from the gearbox and remove the transfer case.
27. Remove the O-ring from the transfer case and discard it.
Installation
1. Clean the mating surfaces of the transfer case and gearbox.
2. Lubricate the new O-ring and install it in place.
3. With the help of a partner, install the transfer case.
4. Screw in the bolts securing the transfer case to the gearbox and pull together their mating surfaces without completely tightening the bolts.
5. Install the transfer box bracket and pull the mating surfaces together.
6. Finally tighten the bolts securing the transfer case to the gearbox. Tightening torque 90 Nm.
7. Completely tighten the transfer case bracket bolts in the following sequence:
- Five bolts securing the bracket to the transfer case with a torque of 50 Nm
- One bolt securing the bracket to the cylinder block with a torque of 45 Nm
- Three bolts securing the bracket to the pallet with a torque of 88 Nm.
8. Install the lower cross member bracket on the pallet, screw in the bolts and tighten them to 100 Nm.
9. Install the lower cross member of the engine, screw in the bolt securing the cross member to the gearbox bracket, but do not tighten it.
10. Attach hoses of system of cooling and fix them collars.
11. Attach the breather hose to the transfer case.
12. Install the damper on the rear axle drive shaft housing, fit the nuts and tighten them to a torque of 25 Nm.
13. Clean the cardan shaft flange and mating flange.
14. Install the cardan shaft on the transfer box drive flange so that the previously applied marks are aligned. Tighten nuts and bolts to 40 Nm.
15. Check up a condition of an epiploon of a power shaft and replace it if it is damaged or worn out.
16. Clean the drive shaft and splines.
17. Install a new retaining ring on the end of the drive shaft.
18. With the help of a partner, move the hub outward and insert the drive shaft into the transfer case, being careful not to damage the oil seal.
CAUTION: Push down on the drive shaft to make sure the retaining ring is seated in its groove and holds the shaft.
19. Install the mudguard panel and secure it with bolts.
20. Establish a reception pipe of system of release.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, volume 1.8, REPAIR WORKS, Downpipe.
21. Reinstall the rear beam.
FRONT SUSPENSION, REPAIR WORKS, Front subframe.
22. Finally tighten the bolt securing the lower cross member to the pallet bracket to 80 Nm.
23. Fill oil into the transfer case housing to the required level.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
24. Fill the gearbox with oil.
MANUAL TRANSMISSION - PG1, ADJUSTMENTS, Transmission oil change in the box.
25. Attach "negative" battery terminal.
26. Fill the engine with coolant.
COOLING SYSTEM: MODIFICATION K, volume 1.8, ADJUSTMENTS, Filling the cooling system.
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