Control Unit: Service and Repair
Rear Differential Carrier (3 Of 3) With Differential Lock:
REMOVAL
1. Remove the bolt and actuator from the differential carrier.
2. Remove the O-ring.
3. If the vehicle has a differential lock, remove the indicator switch and gasket.
4. If the vehicle has a differential lock, remove the shift fork shaft by performing these procedures.
a. Using a hexagon wrench, remove the two straight screw plugs.
b. Remove the spring seat, compression spring and ball.
c. Using a pin punch and hammer, remove the slotted spring pin.
d. Remove the two bolts from the shaft retainer.
e. Using a plastic hammer, remove the shaft retainer.
f. Remove the shift fork shaft.
NOTE: Pull out the shift fork shaft with a screwdriver turned round.
INSTALLATION
1. Differential Lock switch.
a. Install the shift fork shaft.
b. Apply MP grease onto the outer circuit of the fork shaft.
c. Install the fork shaft to match the hole of the shift fork and that of the shift fork shaft.
d. Remove any FIPG material and be careful not to drop oil on the contacting surface of the differential carrier and shaft retainer.
e. Apply Part No.0882-00090, THREE BOND 1281 or equivalent FIPG to the carrier, as shown.
NOTE: Install the shaft retainer within ten minutes after applying the FIPG.
f. Clean the threads of the bolts and retainer bolts holes with toluene or trichloroethylenene.
g. Apply Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent adhesive to two or three threads of the mount bolt end.
h. Tighten the shaft retainer with the two bolts to 24 Nm (17 ft. lbs.).
i. Using a pin punch and hammer, install the slotted spring pin to the shift fork.
j. Shift the fork deeply and keep the differential lock condition.
k. Install the ball, compression spring and spring seat.
l. Clean the threads of two plugs and plug holes with toluene or trichloroethylene.
m. Apply Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent adhesive to the plug threads.
n. Using a hexagon wrench, install and tighten the screw plugs to 22 Nm (16 ft. lbs.).
2. Differential lock.
- Measure the distance between the sleeve and tip of the differential case end side when the differential is free and locked. The standard distances are as follows.
^ LOCK: 17.44 - 18.86 mm (0.6866 - 0.7425 inch).
^ FREE: 32.40 - 33.90 mm (1.2756 - 1.3346 inch).
3.. Install the indicator switch with a new gasket, tightening it to 40 Nm (30 ft. lbs.).
4. . Install the actuator, performing the following procedures.
a. Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole.
b. Ensure that the matchmarks of the pinion of the actuator is in the extent between 0 and 5° clockwise above the center line of the actuator.
NOTE:
^ If the matchmarks is not in this extent, rotate the pinion to be matched.
^ Don't supply the battery positive voltage directly between terminals.
^ If the matchmarks come to the extension limit of the rotation, don't electrify moreover.
c. Install a new Wring to the actuator.
d. Apply a light coat of gear oil on the O-ring.
e. Apply MP grease to the gear part.
f. Insert the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side.
NOTE: Don't damage the O-ring of the actuator.
g. Align the actuator with the long hole and rotate the actuator counterclockwise when the knock pin reaches the right-hand side.
h. Install the actuator to the differential carrier with the bolt so that the outermost rack tooth of the shift fork will fit the matchmarks of the pinion of the actuator. Tighten the bolt to 26 Nm (20 ft. lbs.).