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TRANSFER BOX
26
OVERHAUL
COMPONENT ASSEMBLING
1. 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. Fit each planet gear to its respective
cross-shaft, fit new dished thrust washer to
each gear.
4. Fit cross-shafts, planet gears and dished thrust
washers in rear half carrier.
CAUTION: Ensure that cross-shafts are in
their correct fitted position in rear half
carrier. Do not fit sun gear into rear half
carrier at this stage.
5. Fit retaining ring.
6. Fit a 1.05 mm (0.04 in) thick thrust washer to
front half carrier sun gear, position gear in front
half carrier.
NOTE: This is the thinnest of the thrust
washers available.
7. Fit front half carrier to rear ensuring that
alignment marks are together.
8. Fit bolts and tighten by diagonal selection to 60
Nm (44 lbf.ft).
9. Insert front output shaft into front half carrier,
check that gears rotate freely.
10. Fit output flange on to splines of output shaft,
do not fit flange nut at this stage.
11. Fit 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
whilst 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)