Gearbox and transfer case a / m 1992-98
N - the part is subject to mandatory replacement during disassembly-assembly; 1. Casing (case); 2–6. connectors; 7. Sensor off the front drive axle; 8. Speedometer cable; 9, 12, 13. Shield; 10. Master cylinder; 11. Starter; 14, 15. Side bracket; 16. Clutch housing cover; 17. Torsion support gearbox; 18. Bracket; 19. 2nd crossbar; 20. Cushion rear engine mount; 21. Transfer box shield bracket; 22. Damper; 23. Gearbox with transfer case; 24. Gearbox control lever housing; 25. Gasket; A. Dimensions and threads of bolts indicated by letters A, B, etc.
Removal and installation
Cars 1983-89
1. Move the gearshift lever to neutral position.
2. Remove the gearshift lever and close the hole.
3. Disconnect the battery from the mass and raise the car.
4. Mark the position of the cardan shaft flanges and disconnect the shafts from the gearbox.
5. Designate and disconnect all cables and wires from the gearbox housing, disconnect the wires from the starter.
6. Slightly hang the engine by jacking it into a pallet through a wooden block.
7. Remove the transfer case.
8. Remove the starter.
9. Support the gearbox with a jack truck.
10.. First unscrew the bolts of the clutch housing, then the bolts and nuts securing the cross member, remove the cross member and the fastening parts of the cross member.
11. Slightly lower the engine jack and disconnect the gearbox from the engine by moving the trolley so that the gearbox input shaft disengages.
12. Installation is carried out in the reverse order.
13. Tighten the connections to the following torques: clutch housing bolts - 49 Nm, starter nuts - 27 Nm, transfer box bolts - 12 Nm.
Cars 1990-98
1. Move the gearshift lever to neutral position.
2. Remove the gearshift lever and close the hole.
3. Disconnect the battery from the mass and raise the car.
4. Remove the transfer box guard.
5. Remove the front exhaust pipe.
6. Drain the gearbox oil.
7. Mark the position of the cardan shaft flanges and disconnect the shafts from the gearbox.
8. Remove the boot from the gearbox tail.
9. Designate and disconnect all cables and wires from the gearbox housing.
10. Remove the clutch master cylinder shield, remove the cylinder, set aside and secure.
11. Remove the starter.
12. Slightly hang out the engine by jacking it into a pallet through a wooden block.
13. Support the gearbox with a jack truck.
14. Disconnect the side brackets from the gearbox housing.
15. Remove the bottom cover of the clutch housing.
16. Remove the transfer case bracket.
17. First unscrew the bolts securing the gearbox to the cross member, raise the gearbox by 6 mm and remove the cross member.
18. Remove the gearbox with transfer case.
19. To do this, unscrew the bolts and move the gearbox a little towards the rear of the car, shifting the trolley.
20. Lower and remove the gearbox by tilting the front slightly and pushing forward so as not to touch the rear extreme cross member.
21. Installation is carried out in the reverse order.
22. When installing the gearbox on the engine, align the holes with the drive pins while tilting the engine slightly.
23. Tighten the connections to the required torque.