E-22
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Transmission
4 WD
A. Theory of Operation
The gear (A) which is mounted on spline shaft
constantly mesh with idler gear (B). This gear
transmits power to gear 4WD (C) which spins
freely on output shaft (D) until engaged by
locking collar (E).
When the 4WD lever is pushed down, the locking
collar slides so as to engage with gear 4WD (C).
Power is then transmitted through the output
shaft (D). The propeller shaft is connected to the
4WD axle which give drive to 4WD axle.
B. Dismantling
1. Remove bolt retention for 4WD idler shaft.
2. Take out 4WD idler shaft.
3. Remove 4WD input gear from spline shaft after
removing lock nuts.
4. Remove 4WD idler gear, needle bearing and two
thrust washers.
5. Remove bolt shaft retention 4WD rail.
6. Tap the rail from rear side and remove from front
side of transmission-case.
7. Remove lock plate.
8. Take lever close to wall.
9. Remove fork with ball and spring fitting fork
position as per requirement to avoid flying of
spring and ball.
10. Remove oil seal and circlip from 4WD output
shaft.
11. Tap the output shaft from rear side, take out
washer & locking collar.
NOTE: Take care not to fly out the ball and spring
when taking out locking collar.
C. Cleaning and Inspection
1. Clean all part with suitable solvent.
2. Check all parts for wear, pitting or any crack.
3. Check the spring tension and tilt or damage.
4. Check backlash of gear, locking collar and output
shaft. If it is more than limit, replace it.
D. Assembly
Assemble the removed parts in the reverse
sequence of dismantling.
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