Dismantling
1. Disconnect "negative" battery terminal.
2. Fix a cowl in vertical position.
3. Remove the intake air hoses.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORKS, Intake air ducts.
4. Remove the battery pad.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
5. Remove the starter.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Starter - engine Td4.
6. Remove the transfer case (IRD).
TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.
7. Install tool LRT-54-026 on the drive shaft inner joint. Using the lever, release the left inner joint from the gearbox.
8. With the help of a partner, move the hub outward and remove the left drive shaft from the gearbox.
CAUTION: When pulling out the shaft, keep it in a horizontal position so as not to damage the differential oil seal.
9. Remove and discard the drive shaft retaining ring.
10. Using tool LRT-37-050, disconnect the gear selection rod from the gear selection rod.
11. Disconnect the reversing light switch connector.
12. Using tool LRT-37-051, disconnect and disconnect the clutch actuator tube.
13. Turn out a bolt and disconnect the tire "masses" from the gearbox.
14. Disconnect a socket from the contact gauge of inclusion of the first transfer.
15. Attach the lifting chains to the lifting eyes and lift the engine to remove its weight from the supports.
16. Take out a through bolt of fastening of an arm of a transmission to the left support.
17. Lower the box so that it is clear of the support.
18. Turn out 4 bolts of fastening of the left arm of a support to a transmission and remove an arm.
19. To facilitate subsequent assembly, mark the relative position of the gear selection rod lever and the gear selection rod.
20. Using the LRT-37-049 puller, carefully remove the roll pin connecting the selector lever to the stem.
21. Remove the lever from the stem.
22. Install the lifting eye on the gearbox and secure it with a bolt.
23. Attach lifting chains to the eye and hang the gearbox.
24. Turn away a bolt of fastening of a cover to a transmission.
25. Turn away 7 bolts of fastening of a transmission to the engine.
26. Release a transmission from two directing pins.
27. Lower the gearbox to the floor.
28. If necessary, remove the cover from the gearbox
Installation
1. Clean the gearbox cover.
2. Check that the cover is on the dowel pins.
3. Wipe the mating surfaces of the engine and gearbox, dowel pins and pin sockets.
4. Attach lifting chains to the lifting eye and hang the gearbox.
5. Lift the gearbox and slide it over the dowel pins. Screw in the bolts securing the gearbox to the engine and tighten them to a torque of 85 Nm.
6. Screw in a bolt of fastening of a cover and tighten it. Tightening torque 10 Nm.
7. Wipe down the selector shaft and selector lever.
8. Place the lever on the stem and align the roll pin holes.
9. Install Drift LRT-37-049, press new pin into selector shaft and remove Drift. Check the operation of the gear selector mechanism.
10. Install the bracket on the gearbox, screw in the bolts and tighten them to a torque of 85 Nm.
11. Raise the engine with the gearbox, move the gearbox bracket to the installation site.
12. Insert the through bolt of the left engine mount to the gearbox and tighten it to 100 Nm.
13. Remove the rigging from the gearbox.
14. Disconnect the lifting chains from the engine.
15. Connect the connector to the first gear engagement switch.
16. Connect the connector to the reversing light switch.
17. Put a wire on the gearbox "masses" and tighten the mounting bolt. Tightening torque 25 Nm.
18. Connect the clutch tube quick connector.
19. Install a new retaining ring on the end of the left drive shaft.
20. With the help of a partner, insert the left drive shaft into the gearbox, holding it at the right angle so as not to damage the gearbox oil seal.
21. Install the transfer case (IRD).
TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.
22. Reinstall the starter.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Starter - engine Td4.
23. Replace the battery tray.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Support tray - storage battery.
24. Establish air hoses of inlet system.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORKS, Intake air ducts.
25. Attach "negative" battery terminal.
26. Untie the hood and close it.
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