Disassemble the transfer case in the following order:

  • Remove the nuts and bolts securing the transfer case to the gearbox and separate the components.
  • Remove the thrust ring of the intermediate shaft of the gearbox from the socket.
  • Remove the gaskets from the mating ends.
  • Remove the power take-off cover.
  • Remove the shift cover with stems and levers.
  • Remove the screws and remove the parking brake drum.
  • Remove the rear axle drive shaft flange nut and remove the flange.

Unscrew the bolts securing the brake mechanism to the transfer case and remove it.

Remove the flange from the front axle drive shaft and the front bearing cover of this shaft with the collar.

Remove the bolts connecting the crankcase parts and separate the crankcase so that all internal parts remain on the cover. Do not remove the plugs and the bearing cup unless absolutely necessary.

Disassembly and fault finding of UAZ-3151 transfer case

Remove the stop plate of the shift rods and knock out the shift rods (fig. 2) with a copper hammer while removing the shift forks from them.

At the same time, keep the balls and springs of the latches located in the sockets of the forks from falling out.

Disassembly and fault finding of the UAZ-3151 transfer case

Remove the stopper of the driven gear fitting (Fig. 3) of the speedometer and remove the gear together with the fitting.

Disassembly and fault finding of transfer box UAZ-3151Disassembly and fault finding of the transfer case UAZ-3151

Remove the intermediate shaft and front axle drive shaft bearing caps.

Remove the circlips (fig. 4) of the bearings and knock out the shafts (fig. 5)

Remove the bearings (fig. 6) from the shafts with a puller.

Disassembly and fault finding of UAZ-3151 transfer box

Press out the rear axle drive shaft. Remove the oil deflector, speedometer drive gear from it and remove the bearing with a puller.

Remove the rear axle bearing cap and remove the bearing.

  • * Unscrew the nut of the axles of the levers, press out and remove the levers.
  • * Remove the arm bracket.
  • * On vehicles of the UAZ-3741 family, instead of working according to paragraphs 15, 16, it is necessary to remove the control shafts

Disassembly and fault finding of the UAZ-3151 transfer case

Knock five plugs out of the shift cover.

Knock out the pins (Fig. 7) from the levers towards the removed plugs.

Disassembly and fault finding of transfer box UAZ-3151

Remove the front axle engagement rod, the lock ball through the side hole, the direct and low gear engagement rod.

Until March 1993, the inner ring of the roller bearing was pressed onto the intermediate shaft of the transfer case (Fig. 8), and until July 1994, the shaft fastening nut was installed

Assessing the technical condition of parts

After disassembly, thoroughly wash all parts of the transfer case in kerosene, blow with compressed air and inspect. In doing so, pay attention to the following.

Transfer case housing and its cover.

External inspection reveal cracks, chips, breaks, paying special attention to the lugs of the crankcase and cover, the condition of the threads in the holes, the absence of nicks and burrs on the sealing surfaces.

Crankcase and cover with cracks, chips, kinks, replace.

Fix minor defects. Please note that the crankcase and transfer case cover are machined together and are therefore not interchangeable between transfer cases.

Gears. There should be no chips or nicks on the teeth.

The lateral surface of the teeth should not have any signs of chipping and crushing; there should be no burrs on the end surfaces of the gears.

Seating surfaces must be free of damage and wear that disturbs the alignment of parts. Replace worn gears.

Shafts of the transfer case must not have thread damage. Shaft splines must not have scuffs, burrs, nicks, deep crushing of side surfaces. Replace worn shafts.

Flanges of cardan shafts must not have a spline width of more than 4.645 mm.

Bearings should not have cage damage, ring cracks and chips, raceway spalling, or appreciable radial and axial clearances.

Replace worn bearings.

Cuffs should not have breaks, tears and cracks on the working surface and deformation of the reinforcement.

The wear strip of the working edge should not be more than 2 mm. Replace worn cuffs.

Shift forks must not be cracked, bent or heavily worn. Replace worn parts.

Stemsof the switching mechanism must have securely riveted pins.