Drive shaft seals
Note: A new drive shaft inner joint retaining ring will be required during assembly.
1. Set the parking brake and chock the rear wheels. Jack up the front of the vehicle and place it on stands. Remove the corresponding front wheel.
2. Drain the transmission oil, or prepare a rag to collect the oil spilled during the process of replacing the seal.
3. Release the inner end of the drive shaft from the gearbox, move it to the side and tie it with wire to the suspension elements.
Caution! If it is necessary to disconnect both drive shafts, care must be taken to secure the differential side gears to avoid the risk of them falling out. After releasing the first shaft, insert a piece of metal rod or pipe with a diameter of approximately 26 mm into the shaft seat in the gearbox differential. If necessary, secure the rod from the outside to the gearbox housing with tape. If it is not possible to prevent the side gears from falling into the differential, the only way to remove them is to dismantle the gearbox and deliver it to a car service workshop.
4. Carefully pry the old seal out of its housing using a large flat-head screwdriver.
5. Thoroughly wipe the walls of the seat, then lightly lubricate the outer lips of the new seal with thick grease. Insert the new seal into the seat (with lips inward) and carefully tap it until it stops, using a socket head of the appropriate size or a piece of pipe of the appropriate diameter as a mandrel.
Note: The mandrel should only rest against the hard outer edge of the end face of the seal.
6. Make sure that the oil seal is seated correctly in the gearbox housing, then replace the retaining ring of the inner joint of the drive shaft and insert the latter into the differential.
7. If the transmission oil was drained, fill the gearbox housing with the required amount of fresh oil of the required grade. If the gearbox housing was not drained, check the oil level. If necessary, make the appropriate adjustments.
Gear shift fork axle seal
Note: A new cylinder pin will be required for reassembly.
1. Park the car on a level, horizontal surface, if possible with a hard surface. Firmly apply the parking brake, then jack up the front of the car and place it on supports.
2. Remove the mounting clamp from the transmission end of the gear selector rod, thereby providing access to the cylinder
Note: It would be more correct to replace the standard clamp with a screw or worm clamp during assembly.
3. Using a hammer and punch, knock out the pin and disconnect the gear selector rod from the shift fork shaft. The old pin can be discarded, as it must be replaced during assembly.
4. Remove the protective cover of the fork axle, then use a screwdriver or pliers with long jaws to release the old oil seal of the manual transmission case and remove it from the end of the rod. Prepare to collect the spilled oil - place a suitable drain container under the gearbox case.
 |
 |
5. Check the sealing surface of the axle for defects that could cause the new seal to fail. If necessary, polish the axle journal with fine-grained sandpaper. If serious damage is detected, the axle must be replaced.
6. Lightly lubricate the outer lips of the new seal and carefully place it on the shift fork axle. Sliding the seal along the axle, seat it in the receiving socket in the manual transmission housing. Make sure the seal is seated correctly on the thrust shoulders.
7. Connect the gear selector rod to the shift fork shaft in the manual transmission and align the mounting holes. Use a hammer to tap a new cylindrical pin into the holes and secure it with a screw or worm-type clamp.
8. Finally, adjust the transmission oil level in the gearbox
Primary shaft seal
1. Remove the gearbox from the vehicle and disassemble the clutch release mechanism (see section Removal, condition check and installation of the clutch release mechanism).
2. Loosen the screws securing the clutch release bearing guide sleeve and remove the latter from the manual transmission primary shaft journal. Note: The sleeve may be quite tightly seated and its removal will require some effort.
3. Using a flat-blade screwdriver, carefully pry the old seal out of its seat in the guide coupling assembly.
4. Check the sealing surface of the shaft journal for defects that could cause the new seal to fail. If necessary, polish the journal with fine-grained sandpaper. If serious damage is detected, the shaft must be replaced.
5. Dip the new seal in clean oil and carefully seat it into the receiving socket at the rear of the release bearing guide sleeve (with the jaws facing outwards, i.e. towards the gearbox).
6. Wipe the primary shaft journal again, lubricate it with thick grease, then carefully seat the coupling with the seal seated in it in its regular place. Press the coupling tightly to the surface of the RKPP boat, then screw in the fastening screws and tighten them with the required force.