5 - Front wheel drive
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3) Inspection
1. Wash all components in a suitable cleaning solvent
and allow to air dry.
2. Inspect all bearings for excess wear, score marks,
discoloration from overheating, or other damage.
3. Lubricate all bearings with a clean lubricant before
installation.
4. Inspect the take-off box for. cracks, worn bearing
bores or other damage.
5. Inspect the detent spring for wear, chipped or weak
spring tension.
6. Inspect the detent balls for excess wear or damage.
7. Inspect detent grooves for wear or damage.
8. Inspect all gears for excess wear, chipped or
damaged teeth, or other damage.
9. Inspect the shift fork and pins for excess wear,
bends, or other damage.
4) Assembly
1. Install a new O-ring, 1, on the shift arm, 2.
2. Place the shift fork, 3, in the FWD box.
3. Lubricate the O-ring with petroleum jelly and
install the shift arm into the FWD box, through the
shift fork, 3.
NOTE : Remove the oily stain from the threads of
socket head bolts, 4, shift arm, 2, and shifter fork, 3.
4. Align the holes in the shift fork, 3, with the holes in
the shift arm., 2
5. Place a drop of thread sealant onto the threads of
the two socket head bolts, 4.
6. Install the bolts, 4, through the shift fork and into
the shift arm. Tighten the bolts securely.
7. Install the pins, 11, into the shift fork.
8. Install the spring, 5, and detent balls, 6, into the
drive shaft, 7.
9. While holding the detent balls compressed, install
the sliding gear, 8, onto the drive shaft, 7.
10. Press the sleeve, 9, and bearing, 10, onto the drive
shaft, 7.
NOTE: When installing the sleeve, 9, on the drive
shaft do not use more than 980 N (100 kgf).
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