Contents: Removal ⇩ Installation ⇩
When removing and installing the transfer case, use the LRT 99-010 holder. A drawing of the holder is shown in the figure.
Removal
1. Place the car on a lift.
2. Disconnect the battery.
3. Remove the fan diffuser.
4. Remove the shift lever handle and cover.
5. Raise the car.
6. Drain the oil from the box. Replace the drain plug.
Upper dimensions in mm, lower dimensions in inches. Material - steel. * - drill at the jack installation location.
7. Remove the exhaust downpipe heat shield.
8. Disconnect the oxygen sensor connector.
9. Remove the exhaust gas neutralizer.
10. Remove the frame cross member from the bottom of the box.
11. Remove the speedometer cable heat shield.
12. Disconnect the speedometer cable and secure it to the side.
13. Mark the relative positions of the rear propeller shaft flanges, disconnect the shaft and hang it aside.
14. The same for the front propeller shaft.
15. Loosen the muffler suspension bracket mounting bolts and secure the muffler to the side.
16. Secure the LRT 99-010 holder to the jack.
17. Unscrew the four central bolts of the lower cover of the gearbox housing, move the holder towards the gearbox and secure the gearbox to the holder.
18. Adjust the position of the jack to support the weight of the box.
19. Remove the torque rod between the transfer case and the gearbox.
20. Unscrew the fasteners of the right transfer case support to the frame.
21. The same for the left support. Release the speedometer sensor bracket.
22. Remove the right support cushion.
23. Carefully lower the jack until the parking brake drum is clear of the bottom of the vehicle.
24. Loosen the parking brake cable adjusting nut.
25. Remove the parking brake drum.
26. Remove the brake assembly from the rear output shaft flange.
27. Disconnect the wires from the oil temperature sensor and the lock indicator switch.
28. Disconnect the crankcase ventilation tube of the gearbox. Secure the tube to the side.
29. Remove the locking rod retaining pin and disconnect the rod from the lever.
30. Move the gearbox lever to the low range.
31. Loosen the lock nut of the shift rod and remove the rod from the hinge.
32. Place a temporary support under the main gearbox.
33. Place a wooden block between the support and the gearbox housing.
Seals and covers (lT230T box): Oil leaks may occur at the installation locations of the parts listed below.
1 - input shaft seal, 2 - cover, 3 - front output shaft seal, 4 - crankcase and rear housing joint seal, 5 - rear output shaft seal, 6 - power take-off cover, 7 - gasket.
34. Unscrew the upper and lower bolts securing the transfer case to the gearbox.
35. Screw the guide studs 18G1425 into the main gearbox housing, disconnect the transfer case from the gearbox and remove it.
Installation
36. Set the gear selector to position "P". Engage the low range and differential lock on the transfer case.
37. Secure the transfer case to the holder.
38. Clean the mating surfaces of both boxes. Check that the guide pins on the gearbox are installed correctly.
39. Install the transfer case onto the guide studs. At the same time, insert the shift rod into the hinge.
40. Unscrew the guide pins. Tighten the transfer case fasteners to the gearbox.
41. Reinstall the removed parts.
42. After disconnecting the holder, clean the threads of the four bolts of the bottom cover. Apply Loctite 290 to the threads and tighten the bolts to 25 Nm.
43. Check the operation of the parking brake, adjust if necessary.
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