Car with automatic transmission
Removing the transfer case in combination with automatic transmission must be carried out in the following order.
Prepare fixtures «00.2.030», «24.0.250», «27.1.100», «24.5.301» And «27.1.100».
Set the automatic transmission selector lever to the position «R», remove the exhaust system, stiffening plate and protective panels of the engine compartment.
Remove heat shields (pic. 10.2) and disconnect the wires of the oxygen content sensors in the exhaust gas from the clamps.
Disconnect the front anti-roll bar, rear heat shield, remove the front propeller shaft and drain the oil from the transfer case.
Disconnect the automatic transmission control cable and remove it from the bracket (see fig. 9.7 and fig. 9.8). Disconnect the ventilation duct.
Support the automatic transmission using the tool assembly - «00.2.030» And «24.5.301» And «24.0.250» (pic. 10.3) for automatic transmission «A5S440Z» (5НР24). For automatic transmission «A5S360R» («GM5») - use instead «24.0.250» fixture «24.5.305»
Loosen the bolts (7 pcs., arrows, fig. 10.4) and remove the cross (1) frames. Disconnect the ventilation duct from the RC and release the wires from the clamps on the RC.
Loosen the bolts (arrows, fig. 10.5) propeller shaft fasteners and nuts (arrows, fig. 10.6) intermediate support.
Attention! Prevent the cardan shaft from falling. What can lead to damage to the hinges and the rubber cuff of the CV joint (arrow, fig. 10.7).
Slightly press down on the intermediate bearing of the cardan shaft and remove the shaft from the flange of the secondary (weekend) automatic transmission shaft. Move the propeller shaft to the side and secure it with a wire clamp to the vehicle body.
Support the transfer box with tools «27.1.100» And «00.2.030» (pic. 10.8).
Loosen the bolts securing the gearbox to the automatic transmission and remove the gearbox.
In the case of installing a new RC, it is necessary to unscrew the screws (2, fig. 10.9) and put a vibration damper on it (1).
The installation of the RC should be carried out in the reverse order, while it is necessary:
- check the position and technical condition of the centering sleeves (1, fig. 10.10), if necessary, replace damaged elements;
- lightly lubricate the gear rims (lubricant «Weicon Antisize»);
- check the rubber cushions for fastening the transfer case;
- during installation, the intermediate support must be strictly at right angles (90°) to the cardan shaft;
- Tighten the nuts of the intermediate support to a torque of 21 Nm (2.1 kgf·m);
- replace the self-locking nuts of the cardan shaft;
- when installing the cardan shaft, hold the bolt from turning with a wrench, turn only the nut. M12 nut tightening torque (10.9) – 100.0 Nm (10.0 kgf·m);
- bolts M10 fastening the gearbox to the automatic transmission tighten to a torque of 41 Nm (4.1 kgf·m);
- tighten bolts M12 for fastening the RC to the transverse frame with a torque of 74 Nm (7.4 kgf·m);
- tighten bolts M12 for fastening the transverse frame to the car body with a torque of 74 Nm (7.4 kgf·m);
- tighten bolts M10 for fastening the transverse frame to the car body with a torque of 41 Nm (4.1 kgf·m);
- tighten the automatic transmission control cable fastening nut to a torque of 15 Nm (1.5 kgf·m);
- pour oil into the RC and check its level, which should be at the lower edge of the filler plug (pic. 10.11);
- add oil through the filler hole, replacing the gasket, tighten the M18 plug with a torque of 33 Nm (3.3 kgf·m).
- install stiffening plate.
Attention! When replacing the servomotor or its resistance («ATS500») it is necessary to erase the previous resistance value and carry out programming with «DIS stand».
Transfer Case Replacement Type «ATS500» has a similar technological sequence, while the following features must be taken into account:
- when removing the RC, it is necessary to disconnect the loops (1 and 2, fig. 10.12), remove the screw (3) and remove the resistance of the servomotor RK;
- to remove the servomotor, unscrew the bolt (4) and remove it from the RK;
- before installation, it is necessary to check the centering pins (1, fig. 10.13), if necessary, replace them and apply a light coat of lubricant such as «Weicon Antisize».
Bolt tightening should be as follows:
- tighten bolts М10 of fastening of cross-beam of РК to a body with the moment of 41 Нм (4.1 kgf·m);
- bolts M12 for fastening the frame cross member to the RC, tighten to a torque of 74 Nm (7.4 kgf·m);
- screw M6 for fastening the resistance to the servomotor tighten to a torque of 5.0 Nm (0.5 kgf·m);
- bolt М8 of fastening of the servomotor to RK to tighten the torque of 22 Nm (2.2 kgf·m).
Car equipped with manual transmission
Replacing a transfer case, in combination with a manual transmission, has a similar technological sequence, while devices are used to support it «00.2.030» And «23.0.130».
When installing, replace the seal (1, fig. 10.14) drive shaft (2) RK.
Bolt tightening should be as follows:
- bolt M12 (10.9) hold the flexible coupling of the cardan shaft against turning with a wrench, turn only the nut. Nut tightening torque 55.0 Nm (5.5 kgf·m) with a 90°turn. Bolts M10 (8.8) tighten torque 48 Nm (4.8 kgf·m). Bolts M10 (10.9) tighten torque 64 Nm (6.4 kgf·m);
- M10 bolts (8.8) tighten the fasteners of the RC to the body with a torque of 41 Nm (4.1 kgf·m);
- bolts M12 for fastening the cross member of the frame to the car body, tighten to 74 Nm (7.4 kgf·m).