Inspect

Differential Assembly

Service repair No - 41.20.13

Inspect

1. Check mating surfaces of cross shaft and housing bore for wear.
2. Check core plug in housing for signs of leakage or corrosion; apply Loctite 326 to replacement plug.





3. Measuring across widest portion of finger, check high/low selector finger for wear.
^ Finger width = 15.90 to 15.95 mm (0.625 to 0.627 in).
4. Check bearing track recesses in housing for damage, rectify or replace housing as necessary.
5. If fitted: Carry out inspection of differential lock components using following procedures.
6. Check differential lock selector shaft and housing bore for wear.





7. Measuring across the widest portion, check differential lock finger for wear.
^ Finger width = 15.90 to 15.95 mm (0.625 to 0.627 in).





8. Check differential lock selector finger groove in selector shaft.
^ Groove width - 16.0 to 16-1 mm (0.63 to 0.64 in).





9. Check detent grooves in differential lock selector shaft for wear.
10. Check differential lock detent ball for flat spots and check detent spring for distortion.





11. Check differential lock selector fork for cracks and wear.
12. Check selector fork finger width.
^ Finger width = 7.92 to 7.97 mm (0.311 to 0.313 in).
13. Check differential lock selector fork clips for wear and damage. Check spring for distortion and free length.
^ Spring free length - 84.58 mm (3.33 in).





14. Check dog clutch internal teeth and grooves and teeth on output shaft for wear and damage. Check selector fork groove width.
^ Groove width = 8.05 to 8.20 mm (0.32 to 0.33 in).
15. Carry out the following inspection procedures for all transfer boxes.
16. Check threads and splines of output shaft for damage and wear. Check dog clutch teeth on shaft for wear and damage.





17. 03 MY onwards: Compress high/low selector fork spring and remove retaining clips from each end of spring, remove high/low selector shaft.





18. Check detent grooves in high/low selector shaft for wear. Do not remove fork from shaft unless either component is being renewed. If fork is removed from shaft, coat the threads of the set screw with Loctite 290 prior to assembling.

NOTE: High/low selector shaft fitted to pre 03 MY illustrated.

19. Check width of high/low selector groove.
^ Groove width = 16.0 to 16.1 mm (0.63 to 0.64 in).





20. Check high/low selector fork for cracks and wear. Check selector fork finger width.
^ Finger width = 7.37 to 7.47 mm (0.290 to 0.294 in).
21. 03 MY onwards: Check high/low selector fork clips for wear and damage. Check spring for distortion, check free length of spring:
^ Spring free length = 75 mm (2.95 in)

NOTE: High/low selector shaft, fork and spring fitted to 03 MY transfer boxes may be fitted to pre 03 MY boxes as an assembly.

22. Check differential sun and planet gears for wear, cracks and chipping of teeth.
23. Check cross shafts and recesses in both halves of differential carrier for damage and wear.Ensure planet gears are retained with their respective shafts.
24. Check retaining ring for distortion.
25. Check differential splines for wear and damage.





26. Check high/low hub for cracks, chipping and uneven wear. Check width of selector fork groove.
^ Groove width = 7.5 to 7.6 mm (0.295 to 0.30 in).
27. Check splines and teeth on high/low selector sleeve for uneven wear, cracks, damage and chipping.
28. Check teeth of high and low range gears for cracks, chipping and uneven wear.
29. Check high range gear bush for wear and damage.