TRANSFER BOX (page 2 of 3)

TRANSFER BOX

REPAIRS

41-15

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withdrawn internal transfer gearbox 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 low 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withdrawn internal damage may result.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 
lbf.ft).

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).