Differential Lock: Service and Repair

Front Differential Carrier - 4 WD:

1. Remove the Automatic Disconnecting Differential (A.D.D.) indicator switch.
2. Remove sleeve fork pin, as follows:
a. Using a hexagon wrench, remove the screw plug.





b. Using a pin punch and hammer, remove the pin through the hole of clutch case cover.





3. Separate actuator from clutch case cover and remove sleeve fork, as follows:
a. Remove the two bolts and actuator from the clutch case cover.
b. Separate the actuator from the clutch case cover and remove the sleeve fork.
c. Remove the O-ring from the actuator.

4. Install sleeve fork and actuator into the clutch case cover, as follows:
a. Install a new O-ring to the actuator.
b. Coat the O-ring with Multipurpose (MP) grease.
c. Place the sleeve fork and install the actuator to the clutch case cover.
d. Torque the two bolts.

Torque: 21 Nm (15 ft. lbs.).

5. Install sleeve fork pin, as follows:
a. Using a pin punch and hammer, install the pin through the hole of clutch case cover.
b. Coat the threads of screw plug with FIPG.

FIPG: Part no. 08826 - 00090. three bond 1281 or equivalent

NOTE: Install the sleeve fork pin within ten minutes after applying FIPG.

c. Use a hexagon wrench and install the screw plug.

Torque: 20 Nm (14 ft. lbs.).

6. Install a new gasket and the A.D.D. indicator switch.

Torque: 40 Nm (30 ft. lbs.).