Removing
Place the vehicle over an inspection ditch 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 place the shift lever in neutral. 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 27 (rice. 3-12) lever and with a screwdriver or some other pointed tool, remove the locking sleeve 31 from the groove on the lever rod; remove the rod.
Disconnect the suspension pipes and mufflers at the rear of the vehicle, and then the muffler pipe from the exhaust pipe. Disconnect the clamp securing the front muffler pipe 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 light switch.
Unhook release spring 1 (pic. 3-13) from the clutch release fork 5 and remove the cotter pin 4 from the pusher 6. Disconnect the slave cylinder 8 from the clutch housing. In this case, cylinder 8, connected to the pipeline going to the master cylinder of the clutch release actuator, remains on the vehicle, which eliminates the loss of brake fluid and the need for subsequent bleeding of the hydraulic clutch release actuator.
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; 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.
Disconnect the speedometer flexible shaft from the speedometer drive on the transfer case.
Disconnect the flanges of the cardan shafts of the drive of the front and rear axles from the flanges of the transfer case shafts. 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 swivel wrench 02.7812.9500 the bolts securing the starter to the clutch housing and release it. Loosen the clutch housing cover bolts.
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, stand 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 driven disk hub.
Warning: When removing or installing the gearbox, it is 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 lubricant LSTs-15 or Litol-24 on the splined end of the input shaft and center the clutch disc with mandrel A.70081 (rice. 3-4).