Free Wheel Locking System Overhaul (4WD)

Components

1. Pin
2. Vacuum Hose
3. Free Wheel Engage Switch Assembly
4. Differential Mount Left Bracket
5. Free Wheel Housing
6. Collar

Fastener torques

Torque	Nm (kgf·m)
T = 35	(3.6; 26 ft-lb)
T = 49	(5.0; 36 ft-lb)
T = 49–59	(5.0–6.0; 36–44 ft-lb)
T = 83	(8.5; 61 ft-lb)
T = 59–69	(6.0–7.0; 44–51 ft-lb)

A 2-3 mm (0.079–0.118 in) clearance/gap is also called out on the diagram (component not specified in OCR — verify printed p.223).

Actuator pin removal

1. Pull back dust cover.
2. Use needle-nose pliers and remove pin.
3. Remove collar.

Note: take care not to drop the collar — place a plastic tray under the work area.

Free wheel engagement lamp switch

Switch contact logic: ON = contact between pins No. 1 and No. 2. OFF = no contact.

Component diagram

1. Clutch Sleeve
2. Snap Ring
3. Shift Fork Assembly
4. Split Pin
5. Shift Rod
6. Shift Fork
7. Clutch Gear Assembly
8. C-Clip
9. Bearing
10. Clutch Gear
11. Oil Seal
12. Free Wheel Housing

Bearing removal

1. Place the unit on a press stand and press out bearing as shown (tool MB991015).
2. Install new oil seal (tool printed as “MB992938”/“MB190799” — (verify printed p.225 — illegible, likely MB990799 given step 3 below)).
3. Use bearing installer MB990799 and install new bearing.

Split pin installation

4. Use the guide shown for installing a new split pin. Gap/clearance called out as 0-1 mm (0–0.039 in).

Note: never reuse split pins.

Clutch sleeve installation

5. Install the clutch sleeve with the tapered end facing the driveshaft and the flat side facing the differential gear.