3.3.3. Repair

Dismantling of a distributing box
You carry out dismantling of a distributing box in the following order:
1. Disconnect the transfer case from the transmission as it is specified in the section "Transmission". Remove two laying and a plate (only for the four-speed transmission).

Fig. 203. Distributing box: 1 – safety valve; 2 – sealing ring; 3 – union; 4 – the conducted speedometer gear wheel; 5 – stopper;
6 – stopper of an oil-filling (control) opening; 7 – a gear wheel the leader (a gear wheel of inclusion of a straight line and lowering transfers); 8 – hatch cover; 9,
11 – bearings of a shaft of the drive of the back bridge; 10 – leading gear wheel of a speedometer; 12, 22, 23, 28, 40 – lock rings; 13, 33 – cuffs; 14, 34 – flanges with a reflector; 15, 35 – nuts; 16 – shaft of the drive of the back bridge; 17, 36 – covers; 18 – maslootrazhatel; 19, 37 – bearings of an intermediate shaft; 20, 26 – bearing covers; 21 – intermediate shaft; 24 – gear wheel of inclusion of the forward bridge; 25, 32 – bearings of a shaft of the drive of the forward bridge; 27 – shaft of the drive of the forward bridge; 29 – case cover; 30 – stopper of a drain opening; 31 – case; 38 – cap; 39 – bearing glass; 41 – leading shaft (secondary shaft of a box of transfers); 42 – bearing of the leading shaft (secondary shaft of a box of transfers)


2. Remove a cover of the 8th hatch (see fig. 203) selection of power.
3. Put the gear shifting lever in position of switching off of the forward bridge. Turn off bolts of fastening and remove the switching mechanism, inclining the mechanism back.
4. Turn out screws and remove a drum of the parking brake mechanism.
5. Turn off a nut of the 15th flange of a shaft of the drive of the back bridge and remove a flange 14.
6. Turn off bolts of fastening of the brake mechanism to a distributing box and remove it.
7. Turn off a nut 35 (see fig. 203) a flange of a shaft of the drive of the forward bridge, remove a flange 34 and a cover of the 36th bearing with a cuff 33.
8. Turn off bolts of connection of parts of a case and separate a case so that all internal details remained on a cover. Do not take out a cap, a glass of the 39th bearing and the bearing 37 without extreme need.

Fig. 204. Mechanism of switching of the transfer case:
1 – a rod of a fork of inclusion of a straight line and lowering transfers;
2 – a fork of inclusion of a straight line and lowering transfers; 3 – lock plate of rods; 4 – cap; 5 – case of the transfer case; 6 – rod of a fork of inclusion of the forward bridge; 7 – fork of inclusion of the forward bridge; 8 – pin; 9 – case cover;
10 – hatch cover; 11 – clamp rack; 12 – clamp spring; 13 – switching lever; 14 – lever of forks of inclusion;
15 – protective cover; 16 – pin; 17 – lever spring; 18 – lever case; 19 – plate of fastening of a clamp; 20 – clamp axis; 21 – clamp; 22 – ball clamp; 23 – ball clamp spring; 24 – screw


9. Remove a lock plate of 3 (fig. 204) of rods of switching and beat out rods 1 and 6 copper hammer, having at the same time removed from them switching forks. Thus hold from drop-out balls 22 and the springs of 23 clamps which are in nests of forks.

Fig. 205. Removal of a gear wheel of a speedometer


10. Remove a stopper 5 (see fig. 203) the union of the conducted gear wheel of a speedometer and take out a gear wheel together with the union (fig. 205).

Fig. 206. Removal of lock rings of bearings


Fig. 207. Vypressovka shaft of a distributing box


11. Remove covers of 20 and 26 bearings (see fig. 203) an intermediate shaft and a shaft of the drive of the forward bridge. Remove lock rings of 23 both 28 bearings and a vypressuyta shaft (fig. 206 and 207).
12. Remove a lock ring 22 (see fig. 203) an intermediate shaft, turn off a nut of a shaft of the drive of the forward bridge and remove a stripper bearings from shaft.

Fig. 208. Removal of the bearing from a shaft of the drive of the back bridge


13. Vypressuyte shaft of the drive of the back bridge. Remove from it a maslootra-zhatel 18, the leading gear wheel of a speedometer 10 and remove a stripper the bearing 9 (as shown in fig. 208).
14. Remove a cover 17 (see fig. 203) the back bearing of a shaft of the drive of the back bridge and take out the bearing 11.
15. Unscrew screws 24 (see fig. 204) fastenings of a plate of the 19th clamp.
16. Remove a plate of the 19th fastening of a clamp, a spring of the 17th lever and the lever of 14 forks of inclusion.
17. From a plate of fastening of a clamp to a vypressuyta clamp axis 20 from outside, opposite to a corrugation on an axis. Do not press off without emergency pins 16 and racks of the 11th clamp.

Assessment of technical condition of details
After dismantling carefully wash out all details of a distributing box in kerosene, blow compressed air and examine.
Thus turn attention to the following.
Case of a distributing box and its cover. External survey reveal cracks, chips, breaks, having turned special attention to ears of fastening of a case and cover, a condition of a carving in openings, absence забоин and agnails on the condensed surfaces.
Replace a case and a cover with cracks, chips, breaks. Eliminate minor defects. Keep in mind that the case and a cover of a distributing box are processed in common and therefore are not interchangeable at different distributing boxes.
Gear wheels. On teeths should not be having chopped off and забоин. The side surface of teeths should not have traces you-krashivaniya and a smyatiya, on face surfaces of gear wheels should not be zadirov. Landing surfaces should not have the damages and wear breaking centering of details. Replace worn-out gear wheels.
Shaft of a distributing box should not have damages of a carving, shaft vent – zadirov, agnails, забоин, deep a smyatiya of side surfaces. Replace worn-out shaft.
Flanges of cardan shaft should not have width of hollows of shliyets more than 4,645 mm.
Bearings should not have pov-rezhdeniye of separators, cracks and chips of rings and vykrashivaniya running paths, and also notable radial and axial gaps. Replace worn-out bearings.
Cuffs should not have gaps, vyryvov and cracks on the working surface and deformation of fittings. Strip of wear of a working edge no more
2 mm. Replace worn-out cuffs.
Forks of switching should not have cracks, curvature and big wear. Replace worn-out details.
The clamp should not have cracks and deformations.
The protective cover of the lever of switching should not have gaps and cracks. The cover has to cover the lever and the case of the lever densely.
At repair of a distributing box use these tab. 12.

Assembly of a distributing box
You carry out assembly of a distributing box, since podsborki its knots.
 Assembly of a case
1. Press a persistent glass of the bearing of the leading shaft in a case to an emphasis (if he acted).

Fig. 209. A press fitting of the roller bearing in a case


2. Press the roller bearing (if he acted) in a case (fig. 209), having sustained the size of 6-0,5 mm from a case end face.
3. Screw traffic jams of oil-filling and drain openings.
4. Insert and raschekante a cap of the bearing of an intermediate shaft (if she acted).
 Assembly of covers
1. Press a cuff in a cover to an emphasis.
2. Fill a cavity between rabo-chy edges of a cuff lubricant
Litol-24.
 Assembly of a shaft of the drive of the back bridge

Fig. 210. Napressovka the bearing on a shaft of the drive of the back bridge


Napressuyte on a shaft the bearing to an emphasis (fig. 210).
Assembly of an intermediate shaft
1. Pick up a gear wheel of inclusion of the forward bridge for shaft vents with the minimum gap at its free movement on a shaft.
2. Napressuyte on the back end of a shaft the bearing so that the flute for a persistent ring was displaced outside.
3. Establish a lock ring 22 (see fig. 203).

Fig. 211. An intermediate shaft in collecting


The intermediate shaft in collecting is shown in fig. 211.
 Assembly of a shaft of the drive of the forward bridge
1. Napressuyte on a shaft the bearing from a gear wheel so that the flute for a lock ring was displaced towards a nut.

Fig. 212. Latching of a nut a jam of its fillet in a groove of a shaft and a profile of the tool:
And – the place of latching; B – a tool profile


2. Tighten a nut and stop it, having rumpled a fillet in a shaft groove. Use the tool with  the rounded-off edges (fig. 212) to a jam.
 Assembly of the mechanism of switching of a distributing box
1. Put on the case 18 (see fig. 204) the lever of forks of inclusion a protective cover 15 and press pins 16 (if they acted).
2. Press racks 11 (if they acted) in a plate of the 19th fastening of a clamp, previously having inserted a clamp 21 into grooves of racks. You raskernit racks, as shown in fig. 204.
3. Insert clamp axis 20 into a plate of fastening of a clamp, put on it a clamp 21 and a spring 12, press an axis.
4. Insert into the case 18 the lever 14, a conic spring 17 and a plate of the 19th fastening of a clamp. Squeeze a spring and fix a plate by two screws 24.
 Assembly of a distributing box from podsobrannykh knots
Distributing to-robki you carry out further assembly in the following order:
1. Insert a collected shaft of the drive of the forward bridge into the lower opening of a cover of a case, put on a persistent ring the bearing and establish a shaft against the stop.
2. Insert a collected shaft of the drive of the back bridge into the top opening of a cover of a case.
3. Oil gearbox teeths of the leading gear wheel of a speedometer, put on a gear wheel and a maslootrazhatel a shaft of the drive of the back bridge and napressuyte the bearing with a persistent ring to an emphasis.
4. Insert a collected intermediate shaft into an average opening of a cover of a case, put on a persistent ring the bearing and establish a shaft to an emphasis.
5. Establish laying and covers 20 and 26 (see fig. 203) bearings, fix covers by bolts with spring washers.
6. Establish laying and the cover of the bearing of a shaft of the drive of the back bridge subcollected with a cuff. Fix a cover by two bolts with spring washers.
7. Install the parking brake mechanism on a cover of the bearing of a shaft of the drive of the back bridge and fix it by four bolts with spring washers.
8. Put on a flange, a washer vents of a shaft of the drive of the back bridge, tighten a nut to the full and stop it, having rumpled a fillet in a shaft groove by means of a center punch, as shown in fig. 212.
9. Insert a rod 6 (see fig. 204) with two flutes into a case cover opening so that the copperplated end of a rod was outside. Insert a fork of the 7th inclusion of the forward bridge (wide and short) into a groove of a gear wheel of inclusion of the forward bridge. Insert into a fork nest a spring 23 and a ball 22 clamps.
10. Insert a rod into a fork, squeezing a clamp spring. Press the copperplated end of a rod in a case cover to a flute.
11. Insert into a fork nest 2 inclusions of a straight line and lowering transfers a spring 23 and a ball 22 clamps. Put on a fork a rod 1 with three flutes. Press a rod the copperplated end in a case cover to a flute.
12. Insert a lock plate into flutes of rods and fix it by a bolt with a spring washer.
13. Insert into a fork a gear wheel of inclusion of a straight line and lowering transfers and include it (together with a fork) in the provision of direct transfer.
14. Establish in the case of a gear wheel and shaft collected on a cover, connect a case to a cover and wrap bolts with spring washers.
15. To Napressuyta on a shaft of the drive of the forward bridge the bearing, establish laying, close the bearing a cover with a cuff. Fix a cover by bolts with spring washers.
16. Put on a flange, a washer vents of a shaft of the drive of the forward bridge, tighten a nut to the full and stop it, having rumpled a nut fillet in a shaft groove (see fig. 212).
17. Oil transmission a neck and teeths of the conducted speedometer gear wheel. Put on the union a gear wheel and insert it into an opening of a cover of a distributing box. Stop the union a stopper 51 (see fig. 203) and a bolt with a spring washer.
18. Move a fork of inclusion of the forward bridge in situation "the forward bridge is switched off". Establish laying of a cover of the mechanism of switching to the case socket, place the switching mechanism so that the lever of forks of inclusion entered a groove of a fork of inclusion of the forward bridge (see fig. 204), and fix the switching mechanism by bolts with spring washers.
19. Install laying on the socket of the hatch of selection of power, close the socket a cover and fix a cover by bolts with spring washers. Establish a cover by the convex party of a stamping polygon outside.

Assembly of a distributing box with a box of transfers
You carry out assembly of a distributing box with a box of transfers in the following order:
1. Include the second transfer in a box of transfers.
2. Enter the leading gear wheel of a distributing box into gearing with shaft of the drive of the back bridge.
3. Install a distributing box on a drum of the parking brake mechanism by a flange up.

Fig. 213. Distributing box with sealing laying


4. Grease two sealing laying and a plate (four-speed transmission) on both sides with sealant and establish on the transfer case (fig. 213). Grease the Privalochny plane of the five-speed transmission with sealant.
5. Install a box of transfers on a distributing box so that openings for hairpins and bolts coincided. Turning primary shaft of a box of transfers, combine vents of a secondary shaft of a box of transfers with vents of the leading gear wheel of a distributing box and besiege a box of transfers down.
Establish spring washers under nuts and heads of bolts and, evenly tightening nuts and bolts, connect a box of transfers with a distributing box.
6. Check inclusion of all transfers in a distributing box, turning a hand shaft for a brake drum or a flange of a shaft of the drive of the forward bridge and for primary shaft of a box of transfers.
All transfers have to be enshrined by clamps in provisions of inclusion and neutral situation accurately.
7. Install levers of switching of the transmission and the transfer case at installation of the unit on the car.
Order of installation of the unit on the car see in the section "Transmission".