Assemble the transfer case from a subassembly of its components
Crankcase Assembly
Press the thrust cup of the input shaft bearing into the crankcase until it stops (if it was removed).
Press the roller bearing into the crankcase (Fig. 1), maintaining a dimension of 6-0.5 mm from the end of the crankcase.
Replace the oil drain and oil filler plugs.
Insert and caulk the intermediate shaft bearing plug.
Lid assembly
Press the cuff into the cover until it stops.
Fill the cavity between the working edges of the cuff with Litol-24 grease. Assembling the rear axle drive shaft
Press the bearing onto the shaft until it stops (fig. 2).
Layer Shaft Assembly
Press the roller bearing ring onto the shaft (if provided by the design).
Select the gear for engaging the front axle along the splines of the shaft with a minimum clearance when it moves freely along the shaft.
Press the bearing onto the rear end of the shaft so that the groove for the thrust ring is offset outward.
Install the retaining ring.
On the box of the old design, tighten the shaft fastening nut to failure and lock it by bending the edge into the groove of the shaft.
For bending, use only a tool with rounded edges (see fig. 3).
The intermediate shaft assembly is shown in fig. 4.
Front axle drive shaft assembly
Press the bearing from the gear side onto the shaft so that the groove for the retaining ring is offset towards the nut.
Tighten the nut and lock it by bending the lip into the shaft groove (see fig. 2).
For bending, use only a tool with rounded edges.
The front axle drive shaft assembly is shown in fig. 5.
Assembly of transfer case shift cover
The switching mechanism (disassembled) is shown in fig. 6.
Place the rubber rings into the holes in the stem cover.
Insert the direct and low gear shift rod (it has an oblong flat) into the cover, while putting the short hub lever on it.
Insert a locking ball with a diameter of 11 mm into the lid through the side hole.
Insert the front axle engagement rod (it has a semicircular groove) into the cover, while putting the lever with a long hub on it.
Insert the pins (fig. 7) through the top holes in the cover and drive them flush, securing the levers to the stems.
Place the outer fingers on the rods in different directions, and the levers - with planes to each other.
Insert and emboss the plugs with a mandrel (fig. 8).
- * Install the stamped bracket 5 (see Fig. 15) of the levers on the cover and secure it with three bolts with spring washers.
- * Lubricate the lever axle with Lithol-24 and insert it into the bracket, putting on the axle in succession a polyethylene washer, a direct and a reduction lever, two flat springs, a front axle engagement lever and a polyethylene washer.
In this case, the forks of the lower ends of the levers should engage with the fingers of the rods, and the flat springs should wrap around the rods of the levers.
- * Install the spring washer on the axle and tighten the nut until it stops.
- * Screw the grease fitting into the axis so that its spout is turned towards the cover connector plane.
- * Screw the handles onto the levers.
- * For vehicles of the UAZ-31512 family
Assembly of control shafts for vehicles of the UAZ–3741 family
The transfer box control mechanism is shown in fig. 9.
Install the rubber seal on the spherical end of the front axle engagement shaft, lubricate the sphere with graphite grease and install two crackers.
Put graphite grease into the shaft support and insert the shaft with crackers into the bracket seat.
Lock the crackers (Fig. 10) with a snap ring and close with a rubber cuff.
Install a polyethylene washer (fig. 11) and a tubular rear axle engagement shaft on the control shaft
Assembly of a transfer box from subassemblies
Further assembly of the transfer case in the following order:
Insert the assembled front axle drive shaft into the bottom hole of the crankcase cover, insert the thrust ring into the bearing groove and install the shaft until it stops (Fig. 12).
Insert the assembled shaft (fig. 13) of the rear axle drive into the upper hole of the crankcase cover.
Lubricate the teeth of the speedometer drive gear with gear oil, put the gear on the rear axle drive shaft, put the oil deflector on the shaft and press the bearing with the thrust ring until it stops.
Insert the assembled intermediate shaft into the middle hole of the crankcase cover, put the thrust ring on the bearing and install the shaft until it stops (Fig. 14).
Install the bearing caps and secure them with bolts and spring washers.
Install the parking brake onto the rear axle drive shaft bearing cap.
Put a flange, a washer on the splines of the rear axle drive shaft, tighten the nut to the full and lock it by bending the edge into the groove of the shaft using a center punch, as shown in fig. 3.
Insert the two-groove stem into the hole in the crankcase cover so that the copper-plated end of the stem is out.
Insert the front axle engagement fork (wide and short) into the groove of the front and rear engagement gear. Insert the spring and the retainer ball into the socket of the fork.
Insert the stem into the fork while compressing the detent spring.
Press the copper-plated end of the rod into the crankcase cover up to the groove.
Slide the forward/reverse fork onto the three-groove stem.
Press the stem with the copper-plated end into the crankcase cover up to the groove.
Place the lock plate into the grooves of the rods and secure it with a bolt and spring washer.
Insert the forward and low gear into the fork and engage it (together with the fork) in the direct position.
Set to kacrankcase gears and shafts assembled on the cover, connect the crankcase to the cover and tighten the bolts with spring washers.
Press the bearing onto the front axle drive shaft, install the gasket, close the bearing with a cover with a collar (Fig. 15).
Fix the cover with bolts and spring washers.
Put a flange, a washer on the splines of the front axle drive shaft, tighten the nut to the full and lock it by bending the edge of the nut into the groove of the shaft.
Lubricate the neck and teeth of the speedometer driven gear with gear oil.
Put the fitting on the gear and insert it into the hole in the transfer case cover.
Secure the fitting with a locking plate and a bolt with a spring washer.
Install the shift cover gasket onto the crankcase connector, install the cover with levers and rods so that the levers fit into the grooves of the corresponding forks, and secure it with bolts and spring washers.
Install the gasket on the power take-off hatch connector, close the connector cover and secure the cover with bolts and spring washers.
Install the lid with the convex side of the embossed polygon facing out.
Assembly of transfer case with gearbox
Assemble the transfer case with the gearbox in the following order:
- Engage 2nd gear in the gearbox.
- Engage the drive gear of the transfer case with the rear axle drive shaft.
- Install the transfer case on the parking brake drum with the flange up.
- Install the gasket on the transfer box (fig. 16).
- Install the suspension plate (fig. 17) on the transfer case and press it against the gasket.
- Install the intermediate shaft bearing thrust ring into the transfer case socket.
Place the spacer on the plate.
- Install the gearbox (fig. 18) on the transfer case so that the holes for the studs and bolts match.
- While turning the input shaft of the gearbox, align the splines of the output shaft of the gearbox with the splines of the drive gear of the transfer case and push the gearbox down.
- Install spring washers under the nuts and bolt heads and, evenly tightening the nuts and bolts, connect the gearbox to the transfer case.
Check the inclusion of all gears in the transfer case by turning the shafts by hand on the brake drum or front axle drive shaft flange and on the input shaft of the gearbox.
All gears must be clearly fixed with locks in the on and neutral positions. The downshift should only be engaged after the front axle has been engaged.