Hydraulic 2/4 Wheel Drive Unit
(4WD Spring ON)
Assembly (continued)
10 Using a suitable press, compress the disc springs 8A
and 8B, fit circlip 7.
11 Use levers to remove free play, as shown at B. Measure
the gap between pressure plate 9 and actuating sleeve
15. The gap should be 0.75 - 1.5 mm; 0.030 - 0.059
inches. If necessary fit new shim 10 to achieve the
correct gap. (Shim 10 can be a combination of a single
counter plate, shim (thinner than the counter plate) or
both counter plate and shim). Check that the clutch
pack splines are still aligned - see step 8.
12 Install the 4WD output gear 5 and its needle roller
bearing 6.
13 Install thrust washer 4 and bearing 3.
14 Fit sealing ring 2 and bearing 1.
15 Fit the 2/4WD unit to the gearbox.
16 Apply a thin bead of JCB Multigasket to the 4WD
mating face of the gearbox front case. Fit the case P,
apply JCB Threadlocker and Sealer to bolts D and
progressively torque tighten to 56 Nm, 46 lbf ft.
17 The 4WD clutch and its associated components are
manufactured using a ‘setright’ system. Provided that
components have been assembled correctly, the shaft
end float will be 0.01 to 0.16 mm (0.0004 to 0.006 in).
Rotate the shaft by hand and ensure that it runs
smoothly. Pull the shaft up and down to detect any
excessive end float. If there is excessive end float or the
shaft runs roughly, dismantle the unit and check for
correct assembly.
18 Fit a new oil seal M, fit the output yoke E, and flanged
bolt F. Torque tighten the bolt to 395 Nm; 291 lbf ft.
115-4
Section F Transmission
9803/3280
Section F
115-4
Issue 2*
Synchro Shuttle Gearbox
*
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