Dismantling

1. Give a fixing bolt and remove the speedometer assembly.
2. Give fixing bolts and by a pair of levers, remove the transfer case rear case (exterior of the box to remove the back casing is shown in the accompanying illustration). Try not to damage the mating surfaces of the components.

1 - a plug of switching 2 - catchers 3 - the driven shaft 4 - a speedometer drive 5 - drive chain 6 - front output shaft 7 - central housing 8 - Front housing

Fix the dial gauge on the transfer case, pinning him to the front of the plunger drive sprocket (see. Accompanying illustration) and move the star back and forth. Read the indicator reading device. If the axial backlash is out of range (see. Table sizes and adjustments in the end of this manual), disassemble the driven shaft and carefully examine the condition of the sprocket and associated components. Worn and replace defective parts.

4. Remove the oil drainage and remove speedometer drive gear with the output shaft.
5. Remove the retaining ring fastening 2-4 shift fork drive on your stock (the components of the switching mechanism of the transfer case shown in an accompanying illustration).

1 - an arm 2 - pin 3 - plug 4 - spring 5 - ball 6 - fork mode switching up / down transmission	7 - a plug of switching 2 - 4 8 - switching rod 9 - a plunger retainer 10 - Sleeve 11 - retaining rings

6. Give fixing bolts and by a pair of levers, remove the central transfer case with a driven shaft assembly from the front housing. Try not to damage interfaced surfaces. Remove the thrust washer from the rear bearing of the intermediate shaft.
7. Remove the retaining ring and remove the stem from the 2-4 shift sleeve and spring. Try to remember adjusting position of the sleeve. Discard the lock ring.
8. With the blade of the probe, measure the clearance between the gear and hub reduction gearing up / down transmission (see. Accompanying illustration). If the axial backlash gear downshift out of range, carefully check the condition of the components. Worn or damaged parts, replace.

1 - gear downshift 2 - a nave lowering / overdrive

9. Remove the retaining ring from the front end of the driven shaft.
10. Install a separator between the hub bearing up / down transmission and the step-down gear, get a stripper captures a separator and remove the hub (see. Accompanying illustration). Remove the output shaft gear downshift and roller bearings. With T45 head screws give the bearing retainer in turn beat out the slave and the front output shaft so that there was the possibility of their removal from the central crankcase. Remove the drive chain from the slave and the front output shaft.

1 - separator 2 - a stripper

Assembling the input and output shafts, extracted from the transfer box

1 - the output shaft 2 - bearing 3 - gear clutch 4 - drive sprocket 5 - Coupling 6 - Holder 7 - a gear wheel of lowering peredachti 8 - input shaft

11. Remove the front casing alarm sensor switch 4WD and, on models with AT gauge-switch start authorization (the components of the front transfer case are shown in the accompanying illustration).
12. Unscrew and remove the cap from the front casing of the spring retainers and balls.
13. Remove the shift shaft, clutch shift up / down transmission and the shift fork. Remove the input shaft roller bearing. Remove the plunger lock from the opening fixing of the spring.

1 - the gauge-switch 2 - plug 3 - Male 4 - clutch 5 - an intermediate shaft 6 - Front housing 7 - switching rod

14. Give bolts and remove the holder of a lever bearing of the input shaft from the front housing.
15. Try not to damage interfaced surfaces.
16. Using a hammer with soft brisk beat out the front of the intermediate casing and the input shaft.
17. Loosen the nut finger and apply a hammer with soft brisk blows to end the nut as long as the finger part is out of the control lever. Remove the nut and remove the finger.
18. Remove the control arm from the inner shift lever, pull the shift lever out of the front housing and using a screwdriver to remove the gland. Discard the oil seal.
19. Remove the retaining ring and the spacer ring, and then use a suitable puller and remove the steel plate bearing from the input shaft.

1 - puller 2 - plate 3 - bearing

Components of the input shaft

1 - a lock ring 2 - distance ring 3 - bearing 4 - the input shaft

20. With the help of a stripper remove the bearing from the front output shaft (shaft components are shown in the accompanying illustration):

1 - bearing 2 - Front output shaft

21. Disassemble the machine shaft (see. Accompanying illustration):

1 - bearing 2 - gear clutch 3 - synchronizer ring 4 - drive sprocket 5 - the screws 6 - Holder 7 - Bearings 8 - speedometer drive 9 - Coupling 10 - Spring	11 - sliding keys 12 - Bearings 13 - a lock ring 14 - distance ring 15 - the driven shaft 16 - Bearings 17 - a nave up / down transmission 18 - a gear downshift 19 - Coupling 20 - a lock ring

1. Set the output shaft in the press, resting plates last drive sprocket. Remove the rear shaft bearing, gear couplings, sprockets and synchronizer assembly.
2. Remove the synchronizer ring, then slowly remove the synchronizer sleeve from the drive sprocket, memorizing installation position of the sliding key. Make sure that the keys with a spring popped in the process of removing the sleeve.
3. Remove the bearing retainer, drive sprocket and roller bearing.
4. Remove the output shaft retaining ring and the spacer ring. Install the shaft in the press, the last resting plates front bearing and remove the bearing from the shaft.

22. Disassemble on components of the intermediate shaft (see. Accompanying illustration):

1 - a lock ring 2 - bearing 3 - distance ring 4 - Belleville spring 5 - gear 6 - the intermediate shaft 7 - an adjusting washer

1. Remove the front end of the intermediate shaft lock and remote rings.
2. Using a press, remove the front and rear bearings, then remove the spacer rings, disc springs and toothed ring.

23. Remove the input shaft, then using a stripper or a hammer with sliding brisk remove the drive flange gaskets.