Contents: Removal ↓ Installation ↓
Removal
Remove the caps from the rear wheels, pull the cotter pins out of the axle shafts on the left and right and loosen the castle nuts. Raise the rear of the vehicle and place it on supports.
Remove the engine (see section "Removal and installation the engine").
Raise the rear seat, remove the cover on the frame channel, cut the wire on the square bolts and unscrew them. By moving the gear shift lever away from the inner lever, remove the sliding rod connecting unit. Loosen the crown nuts and remove the brake drums. If necessary, install the rear wheel brakes in place and remove the brake drums using a puller.
Disconnect the brake pipes from the wheel cylinders on each side and remove the clamps from the brake hoses on the axle shaft boots.
Disconnect the parking brake cable from the brake bracket.
Using a cutter, mark the position of the elastic lever relative to the axle housing flange.
Loosen the clutch adjustment nut and remove the clutch cable guide from the gearbox.
Remove the balancer push rod (if present).
Disconnect the wires from the starter.
Disconnect the connector (if any) from the reversing lights.
Loosen the hex nuts on the axle housing support flange and on the shock absorber.
Remove the front gearbox mount (box and rubber-metal support).
Loosen the bolts on the gearbox bracket. Place a jack under the box, pull it forward a little with the help of an assistant, release it onto the jack and remove it from under the car.
Caution! Secure the axle shafts so they do not fall.
Installation
Place the gearbox on the jack, tighten it and install it in place.
Secure the rear gearbox mount. Tighten both bolts on the gearbox bracket to a torque of 230 Nm (23 kgfm).
Caution! If new axle shafts are installed, the rubber-metal mount on the rear gearbox bracket may become deformed. Therefore, first loosen the nuts securing the rubber-metal support to the gearbox bracket, then secure the gearbox bracket with two large bolts, and tighten the nuts of the rubber-metal support again only when the front suspension of the gearbox is secured.
Secure the front gearbox mount. To do this, tighten the hex nuts on the front rubber-metal support.
Slide the sliding rod connection unit onto the sliding rod, tighten the square nut and secure it with wire. Since April 1975, a single-use self-locking bolt has been used.
Caution! The square bolt must be inserted carefully into the recess, otherwise difficulties with gear shifting may occur.
Install the cover on the sliding rod connecting unit, install the rear seat.
Install the shock absorber and balancer push rod (if it exists).
Connect the wires to the starter. Connect the reversing light connector, if available.
Install the clutch cable guide onto the gearbox and tighten the adjusting nut.
Install the parking brake cable into the brake bracket and secure the cable (see chapter "Brake system").
Connect the brake pipes to the wheel brake cylinders, securing the pipe clamps to the axle shaft boots.
Install the wheels with brake drums, tighten the crown nuts.
Adjust and bleed the brakes (see section "Bleeding the brake system").
Install the engine.
Lower the vehicle and tighten the castle nuts to 350 N⋅m (35.0 kg⋅cm).
Caution! Do not tighten the nuts when the vehicle is on supports. If necessary, tighten the nuts further (and not weaken them!) until it is possible to insert the cotter pin.
Visitor comments