TRAVELLING - 2WD-4WD SYSTEM Hydraulic

Clutch - Remove 4WD Clutch

Prior operation:
Disconnect the transmission from the rear axle, for further information refer to Housing - Disconnect (C.20.G)

WARNING
Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -
safety goggles, gloves and shoes.
B026

1. Remove the rear axle sump.

NOTE: Prepare for some oil loss when the sump is
removed.

BAIL08CVT394AVA 1

2. Retrieve the oil supply manifold retaining pin (1) and

O-ring seal (2).

BAIL08CVT388AVB 2

3. Remove the inner clutch guard.

BAIL08CVT322AVA 3

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4. Remove the sliding sleeve from the 4WD clutch drive

shaft.

BAIL07APH546AVA 4

5. Remove the 4WD clutch drive shaft retaining circlip

(1) and shims (2).

BSD2307A 5

6. Using a slide hammer (1) 380000549 and an adap-

tor (2) 380000479 partially withdraw the 4WD clutch
drive shaft (3).

BSD2249A 6

ATTENTION: When the drive shaft is moved forward the 4WD clutch will need to be supported.
7. Retrieve the bearing cap (1) and whilst supporting
the 4WD clutch housing. Completely remove the
4WD clutch drive shaft (2).

BSD2250A 7

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8. Remove the 4WD clutch.

BSD2252A 8

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Clutch - Install 4WD Clutch

WARNING
Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -
safety goggles, gloves and shoes.
B026

1. Position the 4WD clutch assembly.

BSD2252A_139 1

2. Partially install the 4WD clutch drive shaft (2), install

the bearing cap (1),

BSD2250A 2

3. Fully install the 4WD clutch shaft.

BAIL08CVT395AVA 3

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4. Install the shims (2) and the 4WD clutch drive shaft
retaining circlip (1).

BSD2307A 4

5. Using a dial test indicator gauge and a suitable M8

x 1.25 threaded adaptor screwed into the end of the
4WD drive shaft, push and pull the shaft to measure
the end float.
The end float should be 0.05 mm. If away from spec-
ification, add or remove shims accordingly as per the
previous step.

BSE2396A 5

6. Install the sliding sleeve onto the 4WD clutch drive

shaft.

BAIL07APH546AVB 6

7. Install the 4WD clutch inner guard

BAIL08CVT322AVA 7

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8. Thoroughly clean and degrease the rear axle hous-

ing and the rear axle sump mating surfaces. Apply
gasket sealant Loctite 574 to the pattern shown.

24059_115 8

9. Install the oil supply manifold retaining pin (1) and

O-ring seal (2).

BAIL08CVT388AVB 9

10. Install the rear axle sump.

Tighten the bolts to 47 Nm (35 lb ft).

BAIL08CVT394AVA 10

Next operation:
Connect the transmission to the rear axle, for further information refer to Housing - Connect (C.20.G)

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Clutch - Assemble
Prior operation:
Disassemble the clutch, for further information refer to Clutch - Disassemble (D.14.C)

1. Install a new oil seal onto the carrier.

BAIL07APH560AVA 1

2. Install a new oil seal onto the shaft.

BAIL07APH559AVA 2

3. Using a suitable hydraulic press, install the oil seal

carrier onto the shaft.

BAIL07APH558AVA 3

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4. Install the oil seal carrier into the piston.

BAIL07APH557AVA 4

5. Install the pressure plate.

BAIL07APH556AVA 5

6. Install the clutch friction and steel plates.

BAIL07APH555AVB 6

7. Install the end plate.

BAIL07APH554AVA 7

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8. Install the circlip.

BAIL07APH553AVA 8

9. Install the driven gear.

BAIL07APH552AVB 9

10. Install the Belleville washer (1).

BVF0967A 10

11. Loosely install the retaining nut (1).

BVF0965A 11

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12. Using special tool 380000984. (1) and a suitable

hydraulic press, compress the Belleville washer with
a force of 2000 - 2200 Kg ( 4410 - 4850 lbs). Using
special tool 380000984 (2), tighten the retaining nut
(3) to the specified torque value of 15 - 25 Nm ( 11 -
18 lbf. ft).

BVF0966A 12

13. Remove the special tools.

Make a reference mark (1) on the shaft opposite the
cut out (A).
Make an alignment mark (2) on the retaining nut
which is 210 ° (3.5 flats) clockwise from the refer-
ence mark (1) midway between the cut outs (D) and
(E).

BVF0978A 13

14. Using special tool 380000984 and a suitable hy-

draulic press, compress the Belleville washer with a
force of 2000 - 2200 Kg ( 4410 - 4850 lbs).
Using special tool 380000984, rotate the retaining
nut counterclockwise until the alignment mark (2) is
aligned with the reference mark (1).

BVF0979A 14

15. Release the pressure in the hydraulic press and re-

move the special tools.

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16. Stake the retaining nut (1).

BVF0965A 15

Next operation:
Install the clutch, for further information refer to Clutch - Install (D.14.C)

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Clutch - Disassemble 4WD Clutch

Prior operation:
Remove the 4WD Clutch, for further information refer to Clutch - Remove (D.14.C)

1. Unstake the retaining nut (1).

BVF0965A 1

2. Using special tool 380000984 (1) and a suitable hy-

draulic press, compress the Belleville washer. Using
special tool 380000984 (2), remove the retaining nut
(3).
NOTE: Make sure the retaining nut is fully unstaked or
damage to the threads may occur.

BVF0966A 2

3. Remove the special tools and the belleville washer

(1).

BVF0967A 3

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4. Turn the clutch assembly over.

Remove the driven gear.

BAIL07APH552AVA 4

5. Remove the clutch plate retaining circlip.

BAIL07APH553AVA 5

6. Remove the end plate.

BAIL07APH554AVA 6

7. Remove the clutch friction discs and steel plates.

BAIL07APH555AVA 7

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8. Remove the pressure plate.

BAIL07APH556AVA 8

9. Remove the piston from the oil seal carrier.

NOTE: Apply pressure evenly to the piston.

BAIL07APH557AVA 9

10. Using a suitable hydraulic press, remove the shaft

from the oil seal carrier.

BAIL07APH558AVA 10

11. Remove the oil seal from the shaft.

BAIL07APH559AVA 11

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12. Remove the oil seal from the carrier.

BAIL07APH560AVA 12

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Clutch - Overhaul
1. Separate and inspect all components.

BSD2254A 1
Electro Hydraulic Transfer Clutch

1. Retaining Ring 11. Sleeve

2. Shims 12. Bearing Cup
3. Bearing Cup 13. Bearing
4. Bearing 14. Cover
5. Shaft 15. Clutch Plates and Separators (8 off each)
6. Spacer 16. Spacer
7. Piston 17. Retaining Ring
8. Piston Housing 18. Drive Gear
9. Belleville Spring 19. Cover
10. Nut

BSD2253A 2
Piston Assembly

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1. Nut 4. Seal
2. Belleville spring 5. Piston
3. Piston Housing
2. Reassemble piston assembly and clutch plates
(Items 6, 7, 8, 10, 15, 16, 17 Figure 1) Do not install
Belleville spring (item 9) at this stage.
Equally space three feeler gages set to 1.2 mm be-
tween piston housing and spacer.
Press piston housing against clutch plates and screw
down nut until it touches the piston housing

BSD2278A 3

3. Using a vernier measure the position of the face of

the nut to the top of the assembly and scribe an align-
ment mark on nut and housing.

BSD2277A 4

4. Reassemble clutch complete with Belleville spring

and screw down the nut to the same dimension mea-
sured in step 3. Realign the marks on the nut and
housing. The marks made in step 3 ensure that the
nut is positioned in exactly the same place.
NOTE: To assist in tightening the nut the splined shaft can
be held in a vice with soft jaws.

BSD2276A 5

Next operation:
Clutch - Install (D.14.C)

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2WD-4WD SYSTEM Hydraulic - Troubleshooting

NOTE: If the front wheel drive is not functioning correctly, check for any electronic error codes which may be stored.
These are defined by the error code range of 6001 to 7000. To retrieve error codes and review appropriate fault
finding diagnostic charts refer to the relevant chapter in the electrical systems section .
Problem Possible Cause Correction
Four wheel drive engagement switch faulty. Replace the four wheel drive engagement
switch.
Four wheel drive control solenoid valve Repair or replace the solenoid valve.
stuck open.
Worn clutch discs. Replace the clutch discs.
Incorrectly set multi wet-plate clutch re- Adjust the release travel.
lease travel.
Four wheel drive does not Low transmission oil. Refill the transmission to the correct oil
disengage level.
Faulty low pressure circuit. Pressure test the low pressure circuit, for
further information refer to pressure testing
in the hydraulic systems section Priority
valve - Pressure test (A.12.A)).
Faulty four wheel drive engagement circuit. Check the circuit.
Four wheel drive control solenoid valve Repair or replace the solenoid valve.
stuck closed.
Oil leaks through the oil seals with con- Replace any faulty oil seals.
sequent pressure drop: hub, piston, and
transfer box shaft oil seals.

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