Refit

Refit

1. Clean differential components.
2. Lubricate components with gearbox oil.







3. Position differential in soft jawed vice and fit front bearing using tool LRT-41-008.







4. Invert differential in soft jawed vice, and fit low range gear with dog teeth facing uppermost.
5. Fit high/low hub ensuring that machined groove on hub teeth faces towards low range gear.
6. Fit high/low selector sleeve ensuring that alignment marks on hub and sleeve are together.
7. Fit bush to high range gear ensuring collar is uppermost.
8. Fit high range gear and bush onto shaft.







9. Fit new rear bearing using tool LRT-41-008.







10. Using tool LRT-41-007, fit new bearing retaining nut and tighten to 72 Nm (53 lbf.ft). Do not stake nut at this stage.







11. 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 in).

12. If clearance is not as specified, fit a new low range gear and high/low hub and re-check.







13. 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 in)

14. If clearance is not as specified, fit new high range gear and high/low hub and recheck.
15. Using a suitable drift, stake collar of nut into differential shaft recess.







16. Using LRT-51-009, fit new rear bearing track into main casing.
17. Using a straight edge and feeler gauges, check that bearing track is recessed 1 mm (0.04 in) below outer face of main casing.
18. Apply Hylosil RTV 102 sealant to rear output shaft housing face
19. Position housing to main casing
20. Apply Loctite 290 to bolt threads fit housing to main case bolts and tighten to 25 Nm (18 lbf.ft).

Differential Bearing Pre-load Method 1

21. Position high/low selector shaft and fork to differential ensuring that fingers of selector fork are located in selector sleeve.
22. Position differential assembly into main casing ensuring that splines of rear output shaft are engaged in differential.
23. Position new differential front bearing track ensuring that track is seated squarely.
24. Position tool LRT-41-014/3 onto main casing.







25. Screw tool LRT-41-014/4 into tapped hole in main casing and attach suitable DTI to pillar.
26. Position stylus of gauge to setting block and zero gauge.







27. Position stylus onto front bearing track and record reading.
28. Position stylus on opposite side of bearing track and record reading.







29. Obtain average of the 2 readings and record figure.
30. Position depth block tool LRT-41-014/2 and cross bar tool LRT-41-014/1 to front output housing.
31. Position DTI to tool LRT-41-014/1 cross bar and zero DTI on depth block.
32. Position DTI to cross bar and record reading obtained.
33. Using the formula: 3.05 mm (0.120 in)+B-A=D where:
- A=Average of readings to differential front bearing outer track.
- B=Height difference recorded between depth block and cross bar.
- D=Thickness of shim required to give differential bearing pre-load of 0.05 mm (0.002 in).

34. From the resultant figure obtained, select appropriate thickness shim from the range available.
35. Shims are available from 2.00 to 3.25mm (0.08 to 0.13in) thickness, rising in increments of 0.05mm (0.002in).

Proceed To Step 36

Differential bearing pre-load METHOD 2

21. Measure original differential front bearing track shim.
22. Refit original shim into input housing.







23. Fit differential front bearing track using tool LRT-54-003.
24. Locate the front output housing on the transfer box casing.
25. Secure housing with eight retaining bolts and washers, the upper middle bolt being longer than the rest. Torque to 22-28 Nm (16-21 lbf.ft.).
26. Engage high or low gear.

Torque To Turn Method: Option 1
27. Check the rolling resistance of the differential using a spring balance and a length of string wound around the exposed splines of the high/low hub.







NOTE:
- New bearings will register at the top end of the torque range, and used bearings will register at the low end.
- Shims are available in 0.05 mm (0.002 in.) increments.

28. With the correct shim fitted the load to turn should be 1.36 kg to 4.53 kg (3 lb. to 10 lb.).

Proceed To Step 29

Torque to Turn Method: OPTION 2

27. Fit the front output shaft and differential lock sleeve.

NOTE:
- New bearings will register at the top end of the torque range, and used bearings will register at the low end.
- Shims are available in 0.05 mm (0.002 in.) increments.

28. Use a suitable torque wrench to turn the differential. The readings should be 0.56 to 1.69 Nm (5 to 15 lbf.in.).

Proceed To Step 29

Adjustment Both Options

29. If the reading is in excess of the above measurements, remove the front output housing assembly from the transfer gearbox casing.
30. Using a suitable extractor, withdraw the center differential bearing track and change the shim for one of a suitable thickness. (A thinner shim will reduce the rolling resistance.)
31. Fit the new shim and drift the differential bearing track back into its housing until fully home.
32. Continue torque to turn test and shim adjustment until specified parameters are obtained.

Proceed To Step 41







36. Heat the front output housing to 100 °C (210 °F) and fit new output shaft bearing using tool LRT-41-011.
37. Allow housing to air cool.
38. Fit new bearing retaining circlip ensuring that circlip is fully seated.







39. Using tool LRT-41-012, fit new output shaft oil seal.







40. Position selected shim in front output housing and using tool LRT-54-003, fit new differential front bearing track.







41. Fit bearing spacer to output shaft with chamfer on spacer towards threaded end.
42. Fit dog clutch with flange on clutch facing towards splined end.
43. Using a copper mallet, drive output shaft into bearing.
44. Compress differential lock selector spring and fit selector fork.
45. Position selector fork to groove in dog clutch.
46. Fit selector shaft and locate in housing recess, rotate shaft until the two flats for retaining clips are at right angles to the cover plate mating face.
47. Compress selector spring and fit retaining clips at each end of spring.
48. Fit detent ball and spring.
49. Apply Loctite 290 to threads of detent plug.
50. Fit and tighten detent plug, then loosen 2 complete turns.
51. Fit new 'O' ring to differential lock selector housing.
52. Fit selector housing, ensure selector finger is located in shaft recess.
53. Apply Loctite 290 to threads of bolts, and tighten selector housing bolts to 25 Nm (18 lbf.ft).
54. Apply Hylosil RTV 102 sealant to front output shaft housing.
55. Position housing ensuring that output shaft and dog clutch splines are correctly engaged.
56. Apply Loctite 290 to threads of bolts.
57. Fit output shaft housing bolts and tighten in a diagonal sequence to 45 Nm (33 lbf.ft).
58. Fit output flange, new felt washer, steel washer and new retaining nut.







59. Using tool LRT-51-003 to restrain flange, tighten output flange nut to 162 Nm (119 lbf.ft).
60. Fit high/low selector shaft detent ball and spring.
61. Apply Loctite 290 sealant to threads of detent plug.
62. Fit and tighten plug, then loosen 2 complete turns.
63. Fit intermediate gear cluster.