SAFARI

TRANSFER CASE

Install the previously assembled electric shaft cam

and assemble the clutch housing as follows:

Refer

fig. 33

Rotate the shift cam assembly to right so that

the end of the torsion spring contacts with

reduction shift fork inside.

Holding the rail shaft, lift up the fork assembly

slightly. Adjust electric shift cam assembly so that

the roller on reduction shift cam assembly is in

groove in shift cam and button on lockup fork is

on cam end.

Install the clutch housing assembly.

Cover

Fig. 34

Position the cover with the open end facing up on the

table.

Position the end of needle bearingwith the identification

mark up and press into the cover until upper end of

bearing is 40.47 - 40.97 mm below cover face that

contacts with transfer case.

Press the ball bearing into cover and install the snap

ring. Install remaining parts as follows

* Install the four O-rings on the stud bolts of the

clutch coil assembly.

* Install the clutch coil assembly inside the cover

and tighten three nuts.

* Install the bearing and motor bearing into the

cover.

Cover Assembly

Fig. 35

Install the return spring over rail shaft in the transfer

case

Insert the magnet into the transfer case slot

Apply about 1.6 mm bead of Loctite RTV598 to the

transfer case mounting surface. For installation of

cover, align the transfer case with cover. Do not use

excessive force.

38. RAIL SHAFT

39. LOCKUP FORK

59. REDUCTION SHIFT FORK ASSY

100. ELECTRIC SHIFT CAM

101. TORSION SPRING

103. SHIFT SHAFT

18.

OIL SEAL

19.

BEARING

20.

NUT

21.

CLUTCH COIL ASSY

22.

SNAP RING

23.

BALL BEARING

24.

NEEDLE BEARING

25.

CASE COVER

29.

RETURN SPRING

38.

RAIL SHAFT

55.

OUTPUT SHAFT

71.

FRONT OUTPUT SHAFT

103.

SHIFT SHAFT

109.

DOWEL PIN

109

103 29 38

Fig. 33

Fig. 34

Fig. 35