Mount the transfer case on a stand for dismantling and loosen the nuts securing the flanges on the drive shaft and on the drive shafts of the front and rear axles.
Loosen the fastening nuts and remove the crankcase 1 (pic. 3-39) front axle drive assembly with cover 2, lever, fork, differential lock clutch and front axle drive shaft. Remove housing 3 of the speedometer drive assembly with the driven gear of the speedometer drive.
Pic. 3-39. Removing the front axle drive housing:
1 - front axle drive housing; 2 - crankcase cover; 3 - speedometer drive housing.
Removing the lock washer 8 (rice. 3-36), take out the axle 10 and remove the lever 11 of the differential lock. Then remove the cover 7 of the front axle drive housing and remove the spring and the retainer ball 19. Unscrew the locking bolt 3 of the differential lock fork and remove the stem 6, the fork 1 and the lock clutch 2.
Remove the rear cover 31 (rice. 3-35) assembled with the rear axle drive shaft, taking care not to damage the gasket. Then remove flanges 12 from the drive shaft and drive shafts of the front and rear axles.
Remove the adjusting rings of the bearings of the drive shafts of the front and rear axles. Remove shaft 11 (rice. 3-35) front axle drive from the crankcase together with bearing 8, thrust ring and oil deflector 9. Remove the rear axle drive shaft from the rear cover 31 together with bearing 36, thrust ring and oil deflector.
Remove the cap 21 of the input shaft front bearing and the inspection hatch cover.
Remove bracket 13 (rice. 3-36) gear lever assembly with lever. Then, having removed the lock washer, remove the axle and remove the lever 14.
Unscrew the locking bolt of the shift fork 17 and carefully, closing the lock socket with your finger, remove the stem 12 and the lock parts.
Remove front cover 4 (pic. 3-40) together with the differential, then install the differential bearing adjusting ring and remove the bearing assembly with the differential from the front cover.
Pic. 3-40. Removing the transfer box front cover:
1 - intermediate shaft; 2 - drive shaft; 3 - differential; 4 - front cover.
Remove the adjusting rings from the rear bearings of the drive and intermediate shafts and remove both drive and intermediate shafts from the transfer case housing.
Clamping the drive shaft in a vice, remove the thrust ring and rear bearing 11 (pic. 3-41), using a universal puller. Remove low gear 9 with bushing 10, gearshift clutch 8, clutch hub 7, high gear 6 from the drive shaft.
Pic. 3-41. Details of the drive and intermediate shafts:
1 - flange; 2 - stuffing box; 3 - thrust bearing ring; 4 - front bearing; 5 - drive shaft; 6 - gear of the highest gear; 7 - hub; 8 - clutch; 9 - low gear; 10 - bushing; 11 - rear bearing; 12 - bearing adjusting ring; 13 - intermediate shaft bearings; 14 - intermediate shaft.
Disassemble the differential, for which:
- remove retaining ring 1 (pic. 3-42) and spring washer 2 front bearing;
- remove the rear and front bearings from the differential case (pic. 3-43), using a universal puller and stop 67.7853.9559;
- unscrew the bolts of the differential driven gear, mark the risks on the differential housings with their relative position relative to each other and disconnect the housing;
- remove the differential driven gear;
- remove retaining rings 8 (pic. 3-42) and spring washer 14, then press out the axis of the satellites and remove the satellites and gears of the drive axles with support washers.
Pic. 3-42. Transfer Case Differential Details:
1 - retaining ring; 2 - spring washer; 3 - bearing adjusting ring; 4 - differential housing bearings; 5 - driven gear; 6 - front differential case; 7 - front axle drive gear; 8 - retaining ring of the axis of the satellites; 9 - satellite; 10 - rear differential case; 11 - support washer; 12 - rear axle drive gear; 13 - axis of the satellites; 14 - spring washer of the axis of the satellites; 15 - support washer.
Pic. 3-43. Pressing the bearing from the differential housing:
1 - puller А.40005/1/6; 2 - emphasis 67.7853.9559; 3 - bearing.
Press out worn or damaged oil seals from the front axle drive housing, from the front bearing cap, and from the rear cap. Remove the nuts from the axles of the suspension cushion and remove the brackets as an assembly.