Dismantling
1. Remove the transfer case (IRD).
TRANSFER BOX, REPAIRS, Transfer case: Models with K1.8 engine.
TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.
TRANSFER BOX, REPAIRS, Transfer case: Models with KV6 engine.
2. Turn away 8 bolts of fastening of a back cover to a case of a distributing box.
3. Remove the back cover.
4. Remove the intermediate shaft and differential from the input shaft.
5. Remove the drive shaft from the transfer case housing.
6. Remove the two oil seals from the transfer case drive shaft.
7. Take out two epiploons from a case of a distributing box.
Installation
1. Wash the drive shaft and intermediate shaft with differential.
2. Wash the gland seats.
3. Slide the oil seals onto both ends of the input shaft with the oil scraper lips facing out.
4. Insert the drive shaft into the transfer case housing.
5. Put on a protective cover on splines of an intermediate shaft.
6. Carefully install the intermediate shaft onto the drive shaft.
7. Remove the remnants of the old sealant from the mating surfaces of the cover and transfer case housing.
8. Apply a narrow bead of STC 4600 sealant to the mating surface of the rear cover.
9. Install the rear cover on the transfer box housing, sequentially tighten the bolts to 30 Nm.
10. Install the seal lip protector included in the LRT-41-015 kit onto the transfer case splines.
11. Using the flat end of tool LRT-41-015, insert the inner gland into the socket until it stops.
ATTENTION: The oil scraper lips of the oil seals face in opposite directions.
12. Use the opposite end of tool LRT-41-015 to insert the outer gland to a depth determined by the design of the tool.
ATTENTION: It is necessary to protect the working surfaces of the LRT-41-015 tool from damage.
13. Remove the protective cover.
14. Install transfer box (IRD).
TRANSFER BOX, REPAIRS, Transfer case: Models with K1.8 engine.
TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.
TRANSFER BOX, REPAIRS, Transfer case: Models with KV6 engine.
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