Shift on the Fly Unit
Shift On The Fly System
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.
3. Remove actuator assembly and draw out actuator ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.
7. Remove snap ring from front axle case by using snap ring pliers.
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring pliers.
10. Remove inner shaft bearing.
Note: Be careful not to damage the shaft.
11. Remove needle bearing from inner shaft by using a remover J-26941 and sliding hammer J-2619-01.
12. Remove oil seal from front axle case.
Note: Be careful not to damage the front axle case.
Inspection And Repair
Inspect the removed parts. If there are abnormalities such as wear and damage, take corrective action or replace.
Visual Check
1. Check and see if the inner shaft has such abnormalities as wear and damage.
2. Replace the shaft if any signs of deterioration in the gear is present.
Inner Shaft Run-Out
With both end centers supported, rotate the shaft slowly and measure deflection with a dial gauge.
Limit: 0.5 mm (0.02 inch)
Note: Do not heat the shaft to correct its bend.
Inner Shaft Bearing
1. Inspect the inner shaft bearing for any signs of deterioration, replace if uneven.
2. Insert the clutch gear and inspect the needle bearing.
3. Replace the needle bearing if found to be uneven.
Sleeve Condition
Check and see that there is not wear damage, or cracking in the sleeve.
Note: Close inspection of the groove and inner gear are required because those are important parts.
Sleeve Function
Test the sleeve for smoothness by sliding it between the inner shaft and the clutch gear, replace the sleeve if its difficult to slide.
Note: Gear oil should be applied to the contact surface of gear.
Check the width of sleeve center groove.
Limit: 7.1 mm (0.28 inch)
Clutch Gear Condition
Check for wear, damage, crack or any other deterioration in the clutch gear.
Clutch Gear Function
Test the sleeve for smoothness by sliding it across the clutch gear, replace the clutch gear if its difficult to slide.
Note: When inspecting, gear oil should be applied to the contact surface of gear.
Clutch Gear Journal Diameter
Make sure of the size illustrated.
Limit: 36.98 mm (1.456 inch)
Actuator
Check and see that there is no damage, cracking, or other abnormality.
Functional Check
Make sure of function with voltage (12 Volts) applied to terminal 3, 4 and set the tester to terminal 1, 2 in accordance with the table below.
If there is an abnormality, replace the actuator as an assembly.
Note: Be careful not to permit the entry of water or dust into of the actuator.
Dimensional Check
Measure illustrated sizes 1, 2, and 3.
Limit
1=64.3 mm (2.53 inch)
2=6.7 mm (0.26 inch)
3=6.7 mm (0.26 inch)
Reassembly
1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J-41693 and grip J-8092.
2. Force a new needle bearing into inner shaft by using a Installer J-41694 and grip J-8092.
3. Place a new snap ring(internal) in inner shaft.
Force a new inner shaft bearing into the inner shaft.
4. Install snap ring(external).
Note: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle case and insert inner shaft assembly into the front axle case.
Note: Be careful not to damage seal.
6. Install snap ring internal in the groove of front axle case.
Note: Be sure to install the snap ring properly.
7. Apply differential gear oil to clutch gear, then install clutch gear.
8. Apply differential gear oil to sleeve, then install sleeve.
9. Clean contact surface with the front axle and actuator mounting surface. Apply liquid gasket to the contact surface on the front axle case, then install in the housing.
10. Tighten bolts to specified torque.
Torque: 75 Nm (55 ft. lbs.)
11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque.
Torque: 39 Nm (29 ft. lbs.)
12. Apply liquid gasket to the contact surface on the actuator side.
13. Align shift arm with the groove of sleeve and install the actuator.
14. Tighten bolts to specified torque.
Torque: 9 Nm (78 inch lbs.)
15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque.
Torque: 116 Nm (85 ft. lbs.)
16. Pour specified amount of differential gear oil to filler plug.
Front Differential
Oil Capacity: 1.4 Liters (1.48US quarts)
Actuator Housing
Oil Capacity: 0.12 liters (0.13US quarts)
17. Install filler plug through gasket and tighten to specified torque.
Torque: 78 Nm (58 ft. lbs.)