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Assembly

Installation is the reverse order of removal.

PERFORMANCE ORDER

Using a suitable mandrel plant glands in the rear and the central housing and the input shaft bearing retainer is flush with the surface of the components. Grease sponges seals multi-purpose grease on lithium basis. All components lubricate clean oil grades required. Put toothed rings, springs and spacer rings on the intermediate shaft. make sure that the springs were installed with the concave side to the gear. Using a press, install the bearings of the intermediate shaft. Replace the front part of the intermediate shaft remote ring and measure a backlash between a lock ring and the groove (see. Accompanying illustration). Compare result of measurement with the regulatory requirements (see. Table sizes and adjustments in the end of this manual) and pick up a new lock ring required thickness. With the press put the output shaft front bearing (equipped with a screen side of the flange output shaft). Replace the output shaft remote ring and measure a backlash between a lock ring and groove. Compare result of measurement with the regulatory requirements (see. Table sizes and adjustments in the end of this manual) and pick up a new lock ring required thickness. Lubricate front output shaft bearing with oil and set the desired grade on the holder shaft and the front drive wheels. Oil the roller bearing and rotating star, put the bearing on the shaft. Install the synchronizer sleeve, slide keys and a spring on the front drive wheels. Make sure that the clutch was installed recessed from the stars and keys - short ends. Make sure all the key engagement with the spring. Align the notches synchronizer ring with the keys and put a ring on the drive sprocket. Using a press, install the output shaft gear clutch and rear bearing. Make sure that the bearing is equipped with a screen appeared turned to the side of the gear coupling. With reference to the press plates put bearings on the front output and input shafts. Make sure that the outer ring of the bearing retainer of the input shaft was drawn away from the gear. Install the input shaft spacer ring and measure the side clearance between the snap ring and groove. Compare result of measurement with the regulatory requirements (see. Table sizes and adjustments in the end of this manual) and pick up a new lock ring required thickness. Install the oil seal of the lever switch to the internal front housing and lubricate the oil seal lips. Install the inner lever to the front housing. Install the finger, make sure that the lever flat segments proved to be aligned with them, then tighten the fixing nut. Zastuchite input shaft in the front housing with a hammer with soft brisk. Lubricate the mating surface of the bearing and thread mounting bolts sealant Loctite 515 (or equivalent). Tighten bolts with demanded effort (A = 16 ÷ 21 Nm B = 19 ÷ 24 Nm - see. Accompanying illustration). Lubricate the roller bearing grease required class and put it on the input shaft. Zastuchite intermediate shaft to the front crankcase hammer with soft brisk. Install the plug latch to the front housing. Install the shift shaft and the plug on the clutch shift up / down transmission assembly and insert into the front housing. Lubricate the sealing cap and the detent balls and springs. Coat the sealant alarm sensor switch 4WD and, on models with AT gauge-switch start authorization. Install the spring and the plug in the 2-4 shift fork, making sure that the bush was oriented as before. Establish a new lock ring. Set the plug switch modes 2-4 synchronizer sleeve and put the drive chain on the sprockets and the driven output shafts. Exactly set the slave assembly and output shaft in the central housing and using a hammer with soft brisk zastuchite shafts alternately to complete the bearings. If necessary, set the landing bearing holder and tighten the screws. Tighten bolts of the bearing retainer with the required effort. Lubricate the roller bearing and mount it and pinion reduction gearing to the driven shaft. Using a suitable mandrel plant to the driven shaft hub up / down transmission. The hub must be rotated in the direction of the grooves gear downshift. Install retaining ring. With the blade of the probe, measure the clearance between the gear and hub reduction gearing up / down transmission. If the air pump axial backlash is out of range (see. Table sizes and adjustments in the end of this manual) and remove the gear hub and replace defective components. Check the axial play of the intermediate shaft (see. Accompanying illustration): Press measuring flatness to the outer race of the rear bearing of the intermediate shaft and measure the gap between the mating surface of the front edge of the meter housing and flatness (see. Illustration). To determine the desired thickness of shim compare the measurement results with those given in the standard data table: Gap, mm The thickness of the shim, mm 40.6 ÷ 40.5 The puck is not required 40.5 ÷ 40.4 0.1 40.4 ÷ 40.3 0.2 40.3 ÷ 40.2 0.3 40.2 ÷ 40.1 0.4 40.1 ÷ 40.0 0.5 40.0 ÷ 39.9 0.6 If necessary, replace the intermediate shaft bearing shim thickness required. Coat the sealant Loctite 515 (or equivalent), he interfaced surface of the front casing and install a central crankcase assembly, guiding the plug switch on a switching rod and monitor the proper location of the shafts. Install the retaining ring switching rod 2-4 catchers and speedometer drive gear. Lubricate the internal components of the transfer case lubricant required grades. Apply the Loctite 515 (or equivalent) to the gasket surface and install the rear case. Tighten mounting bolts in diagonal order with demanded effort and install the speedometer assembly. Install the transfer case to the car and tighten the lock nuts of the drive flange to the required torque.