Selector Fork Assembly

Selector Fork Assembly

Service repair no - 41.20.40/01

Remove







1. Remove viscous coupling assembly.
2. Remove 17 bolts securing halves of transfer box casing.
3. Carefully break RTV seal and remove front transfer box casing from rear casing.
4. Remove selector fork assembly, interlock spool shaft and reduction hub from rear casing. Collect tube spacer.
5. Remove reduction hub from selector fork assembly.

Refit
1. Clean RTV sealant from front and rear casing mating surfaces.

CAUTION: Do not use a metal scraper as this may damage sealing surfaces.

2. Fit reduction hub to selector fork assembly with hub splines towards the shorter end of shift rail.
3. Fit tube spacer to interlock spool shaft.
4. Engage selector fork cam follower to interlock spool cam track.
5. Fit reduction hub to intermediate shaft and engage interlock spool shaft and shift rail to holes in rear casing.
6. Rotate interlock spool shaft to position reduction hub and selector fork to low ratio position, nearest rear casing half. Ensure tube spacer is in position and selector fork cam follower is correctly engaged in interlock spool.
7. If removed, fit 2 dowels into front casing.
8. Apply a continuous 2 mm bead of RTV sealant to rear casing mating face. Path to be around inside of bolt holes.
9. Fit front casing to rear casing, ensure bolt holes and dowels are aligned before disturbing RTV sealant.
10. Fit bolts securing front casing to rear casing and progressively tighten to 35 Nm. (26 ft. lbs.).
11. Check freedom of rotation of input shaft and that rear output shaft rotates.
12. Fit viscous coupling assembly.