Removing The Coupling Flange Using Tool A.40005/3/9B/9C; Removing The Gear Selector Mechanism; Undoing The Fastening Bolts Of The Gear Unit And The 5Th/Reverse Fork - Lada Niva 4x4 Service Manual

Fig. 3-18. Removing the coupling flange using tool A.40005/3/9B/9C:
1 - flexible coupling flange; 2 - tool A.40005/3; 3 - tool A.40005/3 strap; 4 - tool-
to-flange fastening bolts
Turn out the 3rd/4th gearshift fork fastening bolt. Install lock
41.7816. 4068 on the input shaft or simultaneously engage both
gears. This will prevent the turning of the input, output and inter-
mediate shafts and will allow to do the subsequent operations on
dismantling.
ATTENTION. Since 1997, on the rear end of the gearbox
output shaft the design of the following parts was changed:
- instead of a metal centering ring 26 (see fig. 3-31) and
circlip 1, a rubber centering bush is installed;
- instead of sealing 25 with spring 24, a sealing without a
spring is installed;
- lock washer 22 is replaced with a spring washer;
- nut 23 is sealed with ìÉ-9 or ìÉ-10.
Fig. 3-19. Removing the gear selector mechanism
Remove circlip from the gearbox output shaft end (fig. 3-16).
Unbend the lock washer, undo the nut by several turns to
move the coupling centering ring, and again turn in the nut. Using
a puller A.40006/1 with tool A.40005/4 remove the flexible cou-
pling centering ring from the output shaft end (fig. 3-17).
Remove the coupling centering ring seal with spring from the
output shaft end, undo the nut and using tool A.40005/3/9B/9C
remove the flexible coupling flange (fig. 3-18).
Before removing the rear cover, place the gearshift lever in
neutral position, undo the gear selector mechanism fastening
nuts and remove the gearshift lever (fig. 3-19) in assembly with
the selector mechanism. One of the cover fastening nuts is
undone from the inside of the transmission casing with the bottom
cover being removed. When removing the rear cover it is neces-
sary to move it not only backwards, but also to turn it to exclude
hitting the fifth speed/reverse gear unit.
After removing the output shaft rear bearing inner ring 43
(see fig. 3-12) and distance sleeve 44, loosen the cover fastening
bolts 5 (fig. 3-20) and undo bolts 2 and 4 that are securing the fifth
speed/reverse gear unit. Remove the oil deflector washer 45 (see
fig. 3-12), then bush 1 (fig. 3-21) from the fifth speed gear and
take out rod 1 (fig. 3-22) from fork 2. Thus, distance bush 3 is
removed from the rod. Then remove the gear unit 4 from the inter-
mediate shaft splines.
Fig. 3-20. Undoing the fastening bolts of the gear unit and the
5th/reverse fork:
1 - reverse idler gear; 2 - gear unit fastening bolt; 3 - fork rod; 4 - fork fastening
bolt; 5 - detent cover
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