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, move. V6, REPAIRS, Downpipe: except for North American market.
4. North American Models: Remove the right catalytic converter.
EMISSION CONTROL SYSTEM, Positive crankcase breather valve: Td4 engine, Right bank catalytic converter: KV6 engine, North American market countries.
5. North American Models: Remove the left exhaust manifold gasket.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIR WORK, Gasket (gaskets) left exhaust manifold: North American market countries.
6. Drain the oil from the transfer case.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
TRANSFER BOX, ADJUSTMENTS, Transfer case oil change: North American market countries.
7. Drain the gearbox oil.
AUTOMATIC TRANSMISSION: JATCO, ADJUSTMENTS, Replacement of the working fluid in the box.
8. Turn away 3 bolts of fastening of the right dirt-protective panel and remove the panel.
9. Install tool LRT-54-026 on the drive shaft inner joint. Using the lever, release the drive shaft from the transfer case.
10. 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.
11. Remove and discard the drive shaft retaining ring.
12. For ease of reassembly, mark the position on the front propeller shaft.
13. Raise one rear wheel so that the driveshaft can be rotated to access the bolts.
14. Turn away 6 nuts and remove bolts of fastening of a cardan shaft to a leading flange of a distributing box.
15. 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.
16. Turn away a nut of fastening of a heat-shielding screen to a distributing box.
17. Remove the nut that secures the heat shield to the rear axle drive shaft housing.
18. Turn away 2 bolts of fastening of the heat-shielding screen and remove the screen.
19. Disconnect the breather hose from the transfer case housing.
20. Install a container to collect escaping coolant.
21. Loosen the clamp and disconnect the cooling system hoses from the transfer case.
22. Turn away a bolt of fastening of the lower cross-beam of the engine to an arm of a distributing box.
23. Remove the engine lower cross member. The 'TOP' label must be on top.
24. Turn out 3 bolts of fastening of an arm of a distributing box to the pallet.
25. Turn away 2 bolts of fastening of an arm of a distributing box to a forward plate of the engine.
26. Turn out 5 bolts of fastening of an arm to a distributing box.
27. Remove the bracket.
28. Turn away 4 bolts of fastening of a distributing box.
29. With the help of a partner, separate the transfer case from the gearbox and remove the transfer case.
30. 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 box bracket bolts in the following sequence:
- Five bolts securing the bracket to the transfer case with a torque of 50 Nm
- Two bolts securing the bracket to the front engine bracket with a torque of 50 Nm
- Three bolts securing the bracket to the pallet with a torque of 88 Nm.
8. Install the engine mount lower cross member with the 'TOP' mark facing up. Screw in the bolt, but do not completely tighten it.
9. Attach hoses of system of cooling and fix them collars.
10. Attach the breather hose to the transfer case.
11. Install the manifold heat shield and use your finger to tighten the nut that secures the rear axle drive shaft to the crankcase.
12. Screw in the heat shield mounting bolts to the transfer case bracket and tighten them to 9 Nm.
13. Fit the nut securing the heat shield to the transfer box and tighten it to 45 Nm.
14. Finally tighten the nut securing the heat shield to the rear axle drive shaft housing and tighten it to a torque of 25 Nm.
15. Clean the cardan shaft flange and mating flange.
16. 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.
17. Check up a condition of an epiploon of a power shaft and replace it if it is damaged or worn out.
18. Clean the drive shaft and splines.
19. Install a new retaining ring on the end of the drive shaft.
20. 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.
21. Install the dirt protection panel and secure it with bolts.
22. Establish a reception pipe of system of release.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, Downpipe: except for North American market.
23. Reinstall the rear beam.
FRONT SUSPENSION, REPAIR WORKS, Front subframe.
24. Finally tighten the bolt securing the lower cross member to the transfer case bracket to 100 Nm.
25. 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.
TRANSFER BOX, ADJUSTMENTS, Transfer case oil change: North American market countries.
26. North American models: Install the right catalytic converter.
EMISSION CONTROL SYSTEM, Positive crankcase breather valve: Td4 engine, Right bank catalytic converter: KV6 engine, North American market countries.
27. North American Models: Install the left exhaust manifold gasket.
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIR WORK, Gasket (gaskets) left exhaust manifold: North American market countries.
28. Fill in transmission oil in a transmission.
AUTOMATIC TRANSMISSION: JATCO, ADJUSTMENTS, Replacement of the working fluid in the box.
29. Attach "negative" battery terminal.
30. Fill the engine with coolant.
COOLING SYSTEM: MOD. K, KV6 engine, ADJUSTMENTS, Coolant drain, system flush and fill.
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