SAFARI

TRANSFER CASE

After pressing in the bearing, install the retaining ring.

Press the pin into the front adapter.

Press the oil seal into the front adapter.

Fig. 27

Install the front adapter assembly.Make sure that snap

ring is correctly installed into the groove.

Position the input shaft assembly over front cover and

engage into bearing groove by expanding the ends of

snap ring.

Apply about 1.6 mm bead of sealant on the mounting

face for the transfer case and tighten the six bolts.

Install the breather.

Front Output Shaft

Fig. 28

Press the deflector onto yoke

Position the output shaft in transfer case and install

the end yoke assembly, seal, washer and nut by

holding the end yoke, tighten the nut.

Reduction Shift Parts

Fig. 29

Install new pin, roller into the reduction shift fork.

Press the pin, roller into the reduction shift fork bore.

Ensure that the cam roller turns freely.

Install the two fork facing on the reduction shift shaft

assembly.

Install the reduction shift fork onto previously installed

reduction hub in the transfer case.

Install the output shaft spline into the reduction hub

and engage the output shaft end with input shaft

bearing.

75. SNAP RING

76. OIL SEAL

77. SPIRAL PIN

78. FRONT ADAPTOR

65. NUT

66. WASHER

67. SEAL

68. YOKE ASSY

69. DEFLECTOR

70. YOKE

71. OUTPUT SHAFT (FRONT)

111. TRANSFER CASE

55. OUTPUT SHAFT

57. REDUCTION

HUB

58. SHIFT FORK

FACING

59. REDUCTION

SHIFT FORK

ASSY

Fig. 27

Fig. 28

Fig. 29