Dog Clutch - Differential Lock
Dog Clutch - Differential Lock
Service repair No - 41.20.23
Disassembly
1. Remove 6 bolts securing high/low cross shaft housing to front output shaft housing and remove housing.
2. Note position of longest bolt and remove 8 bolts securing front output shaft housing to main casing and remove housing.
3. Remove 3 bolts securing differential lock selector housing and remove housing.
4. Remove and discard 'O' ring from selector housing.
5. Remove differential warning lamp switch and locknut.
NOTE: Locknut is only fitted to switches up to 03 MY. a modified switch and seating washer is fitted from 03 MY onwards.
6. 03 MY onwards: Remove differential lock warning lamp switch from end of front output shaft housing, discard sealing washer.
7. Remove Alien plug and remove detent spring and ball.
8. Compress differential lock selector fork spring and remove retaining clips from each end of spring.
9. Withdraw differential lock selector shaft from front output housing, recover spring and remove selector fork.
10. Position tool LRT-51 -003 to output shaft drive flange, remove and discard nut.
11. Remove and discard steel and felt washers. Remove output shaft drive flange.
12. Using a copper mallet, drive output shaft from housing.
13. Noting its fitted position, remove bearing spacer from output shaft.
14. Noting its fitted position, remove dog clutch from output shaft.
15. Remove and discard oil seal from housing.
Reassembly
1. Clean differential lock components.
2. Lubricate components with gearbox oil.
3. Using tool LRT-41-012, fit new output shaft oil seal.
4. Fit bearing spacer to output shaft with chamfer on spacer towards threaded end.
5. Fit dog clutch with flange on clutch facing towards splined end.
6. Using a copper mallet, drive output shaft into bearing.
7. Compress differential lock selector spring and fit selector fork.
8. Position selector fork to groove in dog clutch.
9. 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.
10. Compress selector spring and fit retaining clips at each end of spring.
CAUTION: Ensure ends of spring are fully seated in recess in clips.
11. Fit detent ball and spring.
12. Apply Loctite 290 to threads of detent plug.
13. Fit and tighten detent plug, then unscrew 2 complete turns.
14. Fit new 'O' ring to differential lock selector housing.
15. Fit selector housing, ensure selector finger is located in shaft recess.
16. Apply Loctite 290 to threads of bolts and tighten selector housing bolts to 25 Nm (18 lbf.ft).
17. Apply sealant. Part No. STC 3254 to front output shaft housing.
18. Position housing ensuring that output shaft and dog clutch splines are correctly engaged.
19. Apply Loctite 290 to threads of bolts.
20. Fit front output shaft housing bolts and tighten in a diagonal sequence to 45 Nm (33 lbf.ft).
21. Clean threads of differential lock warning lamp switch (es).
22. Up to 03 MY: Fit nut to switch head with counterbore positioned towards switch head.
The nut acts as a spacer to ensure that switch setting is correct. Always ensure that nut is fully tightened to switch head (no Sap).
23. Apply Hylomar PL 32 sealant to threads of differential warning lamp switch(es).
24. Up to 03 MY: Position switch into front output housing until nut bottoms out on housing, tighten nut to 11 Nm (8 lbf.ft).
25. 03 MY onwards: Fit new sealing washers to switches, fir switches to front output housing and tighten to 25 Nm (18 lbf.ft).
26. Operate differential lock selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft. Screw plug in or out until setting is correct.
27. Fit output flange, new felt and steel washers and new retaining nut.
28. Using tool LRT-51-003 to restrain flange, tighten output flange nut to 162 Nm (119 lbf.ft).