SAFARI

29 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 71 103 29 38 55 Fig. 33 Fig. 34 Fig. 35