SAFARI

GEAR BOX G-76

REMOVAL OF GEAR BOX FROM VEHICLE

Place chocks on wheels.

Disconnect battery terminals, electrical connections of starter motor and remove starter motor.

Remove rubber bellow (154) from collar of base plate (156). Loosen lock nut (153) or spacer (in case of Tatamobile)

and remove gear shift lever knob (152). Take out rubber bellow.

Remove screws and take out clamping plate (157) of the rubber bellow - bottom.

Disconnect exhaust pipe from manifold end and main muffler.

For 4x2 vehicles

Disconnect propeller shaft from gear box end and remove center bearing mounting bolts.

Slide the propeller shaft side ways and support it suitably.

Loosen nylock nuts (167) and washer (166) of extension arm support bracket (168) and take it out.

For 4x4 vehicles

Disconnect extension arm support bracket from transfer case housing.

Disconnect electrical connector of electrical shift motor and speed sensor.

Disconnect electrical connector of vehicle speed sensor, In case of petrol engine.

Disconnect front and rear propeller shaft at transfer case end.

Slide the propeller shaft side ways and support it suitably.

Remove circlip (175) from both ends of shift link (172) and take it out along with teflon washers (174)

Remove circlip (175a) and take out pin (178) along with Teflon washer (174a) to disconnect extension arm (151)

from extension arm bracket (150). Remove extension arm assembly.

Disconnect and remove clutch slave cylinder from clutch housing.

Disconnect speedo cable and connector from reverse indicator switch.

Remove clutch housing front sheet metal cover.

Loosen and remove clutch housing mounting bolts.

Loosen and remove gear box adapter housing support - Rear mounting bolts. (4x2) / adapter housing (

4x4

)

Lift the gear box

(4x2)

/ transfer case, gear box assembly

(4x4)

from rear and support the engine suitably.

Remove cross member supporting gear box, from the chassis.

Pull out gear box

(4x2)

/ gear box along with transfer case

(4x4)

to disengage drive shaft from the clutch plate

splines.

Lower the assembly carefully.

Loosen the adaptor housing bolts and separate gear box and transfer case.

(4x4)