Contents: Removal ↓ Installation ↓
Removal
Place the car over an inspection pit or on a lift, put stops under the front wheels and hang the rear axle on one or both sides. Release the parking brake and set the gearshift lever to neutral. Disconnect the wires from the battery.
Remove the front floor mat and outer covers from the transfer case and gearbox levers. Remove the lever hatch covers and seals. Unscrew the handles from the transfer case levers.
Press down on rod 29 (fig 3-12) lever and using 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 hanger and muffle; it at the rear of the car, and then the muffler pipe from the exhaust pipe. Disconnect the clamp securing the exhaust pipe to the gearbox. Using a spanner, unscrew the nuts securing the exhaust pipe to the exhaust manifold and remove the pipe downwards.
Remove the lower clutch housing cover mounting bolts. Disconnect the ground wire from the clutch housing and the wires from the reverse light switch.
Unhook the release spring 1 from the clutch release fork 5 (Fig. 3-13) and remove the cotter pin 4 from the pusher 6. Disconnect the slave cylinder 8 from the clutch housing. In this case, the cylinder 8, connected to the pipeline leading to the master cylinder of the clutch release drive, remains on the vehicle, which eliminates the loss of brake fluid and the need for subsequent bleeding of the hydraulic clutch release drive.
Fig. 3-13. Clutch release drive: 1 - fork release spring; 2 - lock nut; 3 - adjusting nut; 4 - cotter pin; 5 - clutch release fork, 6 - pusher; 7 - bolt for fastening the slave cylinder to the clutch housing; 8 - clutch release drive slave cylinder
Place clamp 2 (A 70025) on elastic coupling 3 (Fig. 3-14) and tighten it. This will facilitate removal and subsequent installation of the elastic coupling. Unscrew nuts 1 and, by turning the intermediate cardan shaft, remove the bolts securing elastic coupling 3 to the flange of the secondary shaft of the gearbox.
Fig. 3-14. Flexible coupling connecting the cardan shaft to the gearbox: 1 - nuts for fastening the flange of the cardan shaft to the elastic coupling; 2 - clamp a 70025; 3 - elastic coupling; 4 - rear engine mount cross member.
Note: It is possible to remove the gearbox assembly with the intermediate shaft. In this case, disconnect the intermediate propeller shaft flange from the transfer case shaft flange.
Disconnect the speedometer flexible shaft from the speedometer drive on the transfer case.
Disconnect the flanges of the transfer case cardan shafts. Lower and move aside the cardan shafts of the axle drive.
Loosen the bolts securing the transfer case brackets to the body and remove it together with the propeller shaft.
Using the 02.7812.9500 socket wrench, loosen the bolts securing the starter to the clutch housing and use it to release it. Loosen the bolts securing the clutch housing cover.
Disconnect the rear engine mount support from crossmember 4 (Fig. 3-14), and then remove the crossmember while supporting the gearbox from below.
The original is on the portal vazbook
Place a jack, trestles or other suitable support under the gearbox housing. Using the A 55035 socket wrench, loosen the mounting bolts and remove the gearbox together with the clutch housing, moving it toward the rear of the vehicle so as to remove the gearbox input shaft from the front bearing and from the clutch driven disk hub.
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. Before installation, apply a thin layer of LSC-15 (LITOL-24) grease to the splined end of the primary shaft and center the driven clutch disc with the A.70081 mandrel (see fig. 3-4).