Transfer Case Actuator: Service and Repair
41.30.03 Actuator - ratio controlRemove
1. Position vehicle on lift and select 'High Range'.
2. Switch off ignition.
3. With neutral selected on automatic gearbox, check that a fuse is not fitted in position 37 of main fuse box. Remove fuse if fitted.
4. Raise the lift.
5. Ensure area to be dismantled is clean.
6. Position a container to collect any spillage.
7. Rotate multiplug anti-clockwise to release and disconnect from ratio control actuator.
8. Remove 3 bolts securing ratio control assembly to transfer gearbox.
9. Avoid disturbing the lead screw which should remain with the transfer gearbox. With extreme care, slowly release the ratio control assembly from the transfer gearbox. Use a small flat blade screw driver to prevent the lead screw moving out with the ratio control assembly, as shown.
CAUTION: If the lead screw is rotated or withdrawn internal transfer gearbox damage may result.
10. Remove the O-ring.
11. Remove bearing only if released.
Refit
1. Ensure 'High Range' is selected by pushing selector shaft fully into transfer gearbox.
CAUTION: If the lead screw is rotated or withdrawn internal damage may result.
2. Clean bearing and mating face.
3. Lubricate and fit bearing, with 'legs' of bearing pointing towards the transfer gearbox, as shown.
4. Clean ratio control assembly and mating face on transfer gearbox.
5. Use a new O-ring, engage splines and fit ratio control assembly to transfer gearbox.
NOTE: The lead screw has a master spline.
6. Fit and tighten bolts securing ratio control assembly to transfer gearbox to 28 Nm (21 ft. lbs.).
7. Connect and secure multiplug to ratio control actuator.
8. Lower the lift.
9. To calibrate a new ratio control assembly, follow the steps below.
10. Fit spare fuse into position 37 in main fuse box.
11. With automatic gearbox in neutral, switch ignition on.
12. Switch off ignition.
13. Remove fuse from position 37.
14. Switch ignition on.
15. Operate switch to perform a high to low shift and back to high.
16. Drive vehicle to perform at least 3 high to low to high shifts cycles at permissible speeds above 6 mph (10 km/h).