Subassembly Overhaul and Assembly
GENERAL1. Lubricate all components with recommended oil.
DIFFERENTIAL
1. Lightly oil threads of differential bolts.
2. Secure rear half of differential carrier in a soft jawed vice.
3. Install each planet gear to its respective cross-shaft, install new dished thrust washer to each gear.
4. Install cross-shafts, planet gears and dished thrust washers in rear half carrier.
CAUTION:
^ Ensure that cross-shafts are in their correct installed position in rear half carrier.
^ Do not install sun gear into rear half carrier at this stage.
5. Install retaining ring.
6. Install a 1.05 mm (0.040 inch) thick thrust washer to front half carrier sun gear, position gear in front half carrier.
NOTE: This is the thinnest at the thrust washers available.
7. Install front half carrier to rear ensuring that alignment marks are together.
8. Install bolts and tighten by diagonal selection to 60 Nm (44 ft lbs).
9. Insert front output shaft into front half carrier, check that gears rotate freely.
10. Install output flange on to splines of output shaft, do not install flange nut at this stage.
11. Install transmission brake drum to output flange, secure drum using 2 nuts.
12. Secure a length of cord around brake drum, attach one end of cord to a spring balance.
13. Tension cord and note load to turn figure recorded on spring balance when brake drum rotates.
NOTE: Used gears should rotate smoothly while new gears will have a "notchy" feel as they rotate.
14. Check figure obtained against specified load to turn figure:
- Used gears = 0.45 kg (1.0 lb)
- New gears = 1.72 kg (3.8 lb)
15. If load to turn figure is below that specified, proceed as follows.
16. Remove front output shaft together with brake drum.
17. Remove 8 bolts securing front half differential carrier.
18. Remove front half differential carrier.
19. Remove front half carrier sun gear and thrust washer.
20. Select a thicker thrust washer from the range -available.
NOTE: 5 thicknesses of thrust washers are available rising in increments of 0.10 mm (0.004 inch) from 1.05 to 1.45 mm (0.04 to 0.06 inch).
21. Position selected thrust washer and sun gear in front half carrier.
22. Install front half carrier to rear ensuring that alignment marks are together.
23. Install bolts and tighten by diagonal selection to 60 Nm (44 ft lbs).
24. Install front output shaft and brake drum and repeat load to turn check.
25. Repeat above procedures as necessary until load to turn figure is as specified; record final figure obtained.
26. Remove brake drum from front output shaft, remove output shaft.
27. Remove bolts securing front half carrier.
28. Remove front half carrier, remove sun gear and thrust washer.
CAUTION: Keep selected thrust washer with sun gear.
29. Remove retaining ring.
30. Remove planet gears and cross shafts.
31. Install a 1.05 mm (0.04 inch) thick thrust washer to rear half carrier sun gear, position gear in rear half carrier.
32. Install planet gears, cross shafts and dished thrust washers in rear half carrier.
CAUTION: Ensure that planet gears are installed to their respective cross-shafts and cross-shafts are installed in their correct location in half carrier.
33. Install retaining ring.
34. Install front half carrier to rear ensuring that alignment marks are together.
CAUTION: Do not install sun gear and thrust washer into front half carrier.
35. Install bolts and tighten by diagonal selection to 60 Nm (44 ft lbs).
36. Invert assembly in vice and then insert rear output shaft into rear half carrier, check that gears rotate freely.
37. Install output flange on to splines of output shaft, do not install flange nut at this stage.
38. Install transmission brake drum to output flange, secure with 2 nuts.
39. Carry out load to turn check using same method as for front half carrier.
40. When load to turn figure is correct, record final figure.
41. Upon completion, install sun gear and selected thrust washer to front half carrier.
42. Install front half carrier ensuring that alignment marks are together.
43. Install bolts and tighten by diagonal selection to 60 Nm (44 Ft lbs).
44. With differential assembled, install rear output shaft and brake drum and check overall load to turn.
- This should be approximately equal to total load to turn figure of both front and rear half carriers added together:
- Used gears = 0.90 kg (2.0 lb)
- New gears = 3.44 kg (7.6 lb)
45. Secure rear half carrier in a soft-jawed vice.
46. Install a new front bearing using tool LRT-41-008.
47. Support front half carrier in a soft-jawed vice.
48. Install low range gear ensuring that dog teeth on gear are towards threaded end of shaft.
NOTE: Use a suitable hollow mandrel to install gear if it is tight on splines.
49. Install high/low hub ensuring that alignment mark made during dismantling is towards threaded end of shaft.
50. Install high/low selector sleeve ensuring that alignment marks on hub and sleeve are together.
51. Install bush to high range gear ensuring that collar on bush is on opposite side of gear to the dog teeth.
52. Install high range gear and bush ensuring that collar on bush is towards threaded end of shaft.
53. Install a new rear bearing using tool LRT-41-008.
54. Install a new bearing retainer nut, tighten to 72 Nm (53 ft lbs) using tool LRT-41-007.
CAUTION: Do not stake nut at this stage.
55. Slide high/low selector sleeve and hub away from low range gear.
56. Using feeler gauges, determine clearance between low range gear and high/low hub:
- Clearance = 0.05 to 0.15 mm (0.002 to 0.006 inch)
57. If clearance is not as specified, install a new low range gear and high/low hub and re-check.
58. Slide high/low selector sleeve and hub away from high range gear.
59. Using feeler gauges, determine clearance between high range gear and high/low hub.
- Clearance = 0.05 to 0.15 mm (0.002 to 0.006 inch)
60. If clearance is not as specified, install new high range gear and high/low hub and re-check.
61. Using a round nosed punch, stake collar of nut into recess in differential shaft.
MAIN CASING
1. Install a new differential rear bearing race using tool LRT-51-009.
2. Using a straight edge and feeler gauges, check that bearing race is recessed 1.0 mm (0.04 inch) below outer face of main casing.
3. Using a suitable mandrel, install a new mainshaft input gear bearing race.
CAUTION: Ensure bearing races are seated squarely in recesses.
4. Lubricate a new mainshaft oil seal with recommended oil.
5. Invert main casing and install oil seal, lip side facing inwards, using tool LRT 7-014.
MAINSHAFT INPUT GEAR BEARING HOUSING
1. Ensure bearing race recess in housing is clean.
2. Position a 3.15 mm (0.12 inch) thick shim in bearing housing.
NOTE: This is the thinnest of the shims available.
3. Using a suitable mandrel, install new mainshaft input gear bearing race.
CAUTION: Ensure bearing race is seated squarely in recess.
MAINSHAFT INPUT GEAR ASSEMBLY
1. Lubricate new bearings with recommended oil.
2. Secure hand press LRT-99-002 in a vice.
3. Position collars LRT-41-003 in hand press.
4. Position new bearing on collars.
NOTE: Smallest diameter of bearing must be towards collars.
5. Locate end of mainshaft in bearing, press mainshaft through bearing.
6. Repeat above procedure for remaining bearing.
INTERMEDIATE GEARS.
1. Lubricate new bearings and bearing races with recommended oil.
2. Install new circlips into intermediate gears.
CAUTION: Ensure that circlips are correctly seated.
3. Install new bearing races using tools LRT-41-006 and LRT-99-003.
CAUTION: Ensure bearing races are fully seated against circlips.
4. Retain bearings with intermediate gears.
REAR OUTPUT HOUSING
1. Heat rear output housing to 100°C (212°F).
2. Install new output shaft bearing using tool LRT-41-011.
3. Allow housing to air cool.
4. Install new bearing retaining circlip ensuring it is seated in groove.
5. Lubricate a new output shaft oil seal with recommended oil.
6. Install oil seal using tool LRT-41-012.
NOTE: Use end of tool marked "REAR" to install oil seal.
7. Check that oil seal is just contacting circlip.
8. Slide speedometer drive gear and spacer on to output shaft.
9. Position rear output housing on bed of hand press.
10. Locate threaded end of output shaft in bearing.
11. Position thrust button LRT-37-11/2 between end of output shaft and press mandrel.
12. Press output shaft into bearing.
13. Install mud shield with open face of shield towards oil seal.
CAUTION: Do not install output shaft flange at , this stage.
14. Install speedometer driven gear into rear output housing ensuring that gear teeth are engaged with drive gear.
15. Lubricate a new O-ring with recommended oil and install to driven gear housing.
16. Install driven gear housing.
17. Lubricate a new oil seal with recommended oil, install seal with lip towards driven gear housing.
FRONT OUTPUT HOUSING
CAUTION:
^ Do not carry out assembly operations until differential bearing pre-load has been established
^ See Assembly of Transfer Case.
1. Heat front output housing to 100°C (212°F).
2. Install new output shaft bearing using tool LRT-41-011.
3. Allow housing to air cool.
4. Install new bearing retaining circlip ensuring it is fully seated in groove.
5. Lubricate a new output shaft oil seal with recommended oil.
6. Install oil seal using tool LRT-41-012.
NOTE: Use end of tool marked "FRONT" to install oil seal.
7. Check that oil seal is just contacting circlip.
8. Position selected shim in front output housing.
9. Install differential front bearing race using tool LRT-54-003.
10. Install bearing spacer to output shaft ensuring that chamfer on spacer is towards threaded end of shaft.
11. Install dog clutch ensuring that flange on clutch is towards splined end of shaft.
12. Using a mallet, drive output shaft into bearing.
HIGH/LOW CROSS SHAFT HOUSING
1. Lubricate cross shaft and new O-ring with recommended oil.
2. Insert cross shaft into housing, position high/low selector finger on shaft.
3. Install O-ring to shaft, locate end of shaft in hollow plug.
4. Slide O-ring to end of shaft.
5. Align hole in high/low selector finger with recess in cross shaft.
6. Apply Loctite 290 to threads of setscrew, install and tighten screw.
7. Apply Hylomar PL32 sealant to threads of neutral warning lamp switch, if installed.
- Install switch, do not tighten locknut until switch has been adjusted.
NOTE: Switch must be adjusted after transfer box is installed in vehicle.
DIFFERENTIAL LOCK SELECTOR
1. Lubricate new O-rings with recommended oil, install to selector finger shaft and housing.
2. Insert selector finger shaft into housing.
3. Install selector lever ensuring that relative positions of lever and finger are as shown.
4. Install washer and new self-locking nut, tighten nut to 15 Nm (11 ft lbs).