Removing
Position the vehicle over a pit or on a lift, chock the front wheels and hang the rear axle on one or both sides. Release the parking brake and place the shift lever in neutral position Disconnect the wires from the battery.
Remove the front floor mat and outer covers from the transfer case and transmission levers. Remove covers of hatches of levers and sealants. Unscrew the handles from the transfer case levers.
Press down on rod 29 (pic 3-12) lever and with a screwdriver or some other pointed tool, remove the locking sleeve 33 from the groove on the lever rod; remove the rod.
Disconnect the pipe suspension and turn off; her at the back of the car, and then the muffler pipe from the exhaust pipe. Disconnect the clamp securing the intake pipe to the gearbox. Using a wrench, unscrew the nuts securing the intake pipe of the mufflers to the exhaust manifold and remove the pipe down.
Loosen the lower clutch housing cover bolts. Disconnect the connection wire from «weight» from the clutch housing and wires from the reversing light switch.
Disconnect the retracting spring 1 from the clutch release fork 5 (pic. 3-13) and remove the cotter pin 4 from the pusher 6. Disconnect the working cylinder 8 from the clutch housing. In this case, the cylinder 8, connected to the pipeline going to the master cylinder of the clutch release drive, remains on the car, which eliminates the loss of brake fluid and the need for subsequent pumping of the hydraulic clutch release drive.
Pic. 3-13. Clutch Release Drive: 1 - retractable fork spring; 2 - locknut; 3 - adjusting nut; 4 - cotter pin; 5 - clutch release fork, 6 - pusher; 7 - a bolt of fastening of the working cylinder to the clutch housing; 8 - working cylinder of the clutch release drive
Put on the elastic sleeve 3 (pic. 3-14) collar 2 (A 70025) and tighten it. This will facilitate the removal and subsequent installation of the flexible coupling. Unscrew nuts 1 and, turning the intermediate cardan shaft, remove the bolts securing the flexible coupling 3 to the flange of the output shaft of the gearbox.
Pic. 3-14. Elastic coupling connecting the cardan shaft with the gearbox: 1 - nuts for fastening the cardan shaft flange to the elastic coupling; 2 - clamp a 70025; 3 - elastic coupling; 4 - cross member of the rear engine mount.
Note. You can remove the gearbox assembly with the intermediate shaft. In this case, disconnect the flange of the intermediate cardan shaft from the flange of the transfer case shaft.
Disconnect the speedometer flexible shaft from the speedometer drive on the transfer case.
Disconnect the flanges of the driveshafts of the transfer case. Lower and move aside the axle drive shafts.
Unscrew the bolts securing the transfer case brackets to the body and remove it together with the propeller shaft.
Unscrew the bolts securing the starter to the clutch housing with a socket wrench 02.7812.9500 and loosen it. Remove the bolts securing the clutch housing cover.
Disconnect the rear engine mount from the cross member 4 (pic. 3-14), and then remove the cross member while supporting the gearbox from below.
Place a jack, trestle or other suitable support under the gearbox housing. Using a socket wrench A 55035, unscrew the mounting bolts and remove the gearbox together with the clutch housing, shifting it to the rear of the car so as to remove the gearbox input shaft from the front bearing and from the hub of the clutch disc.
Warning. When removing or installing the gearbox, it is strictly forbidden to rest the end of the input shaft on the thrust flange of the clutch pressure spring, so as not to deform the clutch connecting plates.
Installation
The gearbox is installed in the reverse order of removal. Apply a thin layer of LSTs-15 grease before installation (LITOL-24) on the splined end of the input shaft and center the clutch disc with the mandrel A.70081 (see fig. 3-4).