Shift On The Fly System

Transcription

1 Shift On The Fly System Shift On The Fly System and Associated Parts 4C RY00007 Legend (1) Filler Plug (2) Bolt (3) Oil Seal (4) Snap Ring(External) (5) Inner Shaft Bearing (6) Snap Ring(Internal) (7) Inner Shaft (8) Needle Bearing (9) Clutch Gear (10) Sleeve (11) Housing (12) Front Axle Drive Shaft(LH side) with Bracket (13) Bolt (14) Actuator Assembly (15) Bolt

2 4C 20 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. 10. Remove inner shaft bearing. NOTE: Be careful not to damage the shaft. 412RW Remove needle bearing from inner shaft by using a remover J and sliding hammer J RW Take out inner shaft from front axle case. 9. Remove snap ring from inner shaft by using snap ring pliers. 12. Remove oil seal from front axle case. NOTE: Be careful not to damage the front axle case. 412RS RW016

3 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. 4C 21 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 in) NOTE: Do not heat the shaft to correct its bend. 412RS RW Replace the shaft if any signs of deterioration in the gear is present. Inner Shaft Bearing 420RS008 Legend (1) Inner Shaft Bearing (2) Inner Shaft (3) Clutch Gear 412RW 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.

4 4C 22 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. Clutch Gear Condition Check for wear, damage, crack or any other deterioration in the clutch gear. Clutch Gear Function Sleeve Function 412RY00039 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 (1.28 in) 412RY00038 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: mm (1.456 in) 412RY RW022

5 4C 23 Actuator Check and see that there is no damage, cracking, or other abnormality. Functional Check NOTE: Be careful not to permit the entry of water or dust into of the actuator. Dimentional Check Measure illustrated sizes 1, 2, and RY00041 Limit 1=64.3 mm (2.53 in) 2=6.7 mm (0.26 in) 3=6.7 mm (0.26 in) 412RY00010 Reassembly 1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J and grip J RY00009 Wake sure of function with boltage (12V) applied to terminal 3, 4 and set the tester to terminal 1, 2 in accordance with the table below. State Trminal 3 Trminal 4 Electric circuit between Function terminal 1 & 2 A +12V Ground OK 2WD B Ground +12V NONE 4WD If there is an abnormality, replace the actuator as an assembly. 412RW034

6 4C Force a new needle bearing into inner shaft by using a Installer J and grip J NOTE: Be sure to install the snap ring properly. 412RS Place a new snap ring(internal) in inner shaft. Force a new inner shaft bearing into the inner shaft. 412RW 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. 4. Install snap ring(external). NOTE: Be careful not to damage the inner shaft. 412RS 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. 412RW Tighten bolts to specified torque. Torque: 75N m(55 lb ft) 11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque. Torque: 39N m (29 lb ft)

7 4C Apply liquid gasket to the contact surface on the actuator side. 412RW Align shift arm with the groove of sleeve and install the actuator. 14. Tighten bolts to specified torque. Torque: 9N m(78 lb in) 15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque. Torque: 116N m (85 lb ft) 16. Pour specified amount of differential gear oil to filler plug. Front Differential Oil Capacity: 1.4lit (1.48US qt) Actuator Housing Oil Capacity: 0.12lit(0.13US qt) 17. Install filler plug through gasket and tighten to specified torque. Torque: 78N m (58lb ft)