UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Differential Lock System
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-49
16
∆ CAUTION
• Be sure threads of cable are engaged in ball joint socket at least 1/4 inch (6.35 mm). If ball joint
socket comes loose from the cable, the F&R shifter will not operate properly.
For major adjustments, the cable retaining nuts (5) must be loosened and adjusted. When the cable is prop-
erly adjusted, with the Forward/Reverse handle (9) (Figure 16-116, Page 16-48) in the NEUTRAL position,
the shift lever of the transaxle will also be in the NEUTRAL position (Figure 16-115, Page 16-47). Retighten
nuts (5) at transaxle to 22 ft-lb (29.8 N·m); retighten nuts (5) at the F&R assembly to 43 in-lb (4.9 N·m).
DIFFERENTIAL LOCK SYSTEM
Read DANGER and WARNING on page 16-1.
If the differential lock cable is damaged in any way, it must be replaced. See following WARNING.
∆ WARNING
• If for any reason the differential lock system is not operating correctly, the system must be
repaired or replaced before attempting to operate the vehicle. With the differential lock
engaged, vehicle turning functions are greatly reduced. Failure to heed this warning could
result in loss of vehicle control and severe personal injury.
DIFFERENTIAL LOCK SYSTEM INSPECTION
The differential lock system should periodically be inspected for proper operation.
1. Place chocks at the front wheels and lift the rear of the vehicle with a floor jack. Then place jack stands
under the axle tubes to support the vehicle. See WARNING on page 16-1.
2. With the differential lock handle in the forward position (unlocked), rotate one of the rear wheels by
hand. The wheel should be fairly easy to rotate and the other rear wheel should rotate in the opposite
direction, indicating that the differential lock is not engaged. If this is not the case, the differential han-
dle, cable or housing must be repaired or replaced before attempting to drive the vehicle.
3. With the wheels at rest, pull the differential lock handle toward the rear of the vehicle (locked position).
Observe the cable end and differential lock arm on the differential lock housing. The cable should move
freely when the handle is moved. Initially, there may be slack in the cable at the differential housing.
Rotation of the rear tire will eliminate this slack when the differential lock is fully engaged.
4. With the differential lock handle in the rear position (locked), rotate one of the rear wheels by hand. The
wheel should be a great deal harder to rotate and the other rear wheel should rotate in the same direc-
tion, indicating that the differential lock is engaged. If this is not the case, the differential handle, cable
or housing must be repaired or replaced before attempting to drive the vehicle.
DIFFERENTIAL LOCK CABLE REMOVAL
1. Place the differential lock handle in the disengaged (unlocked) position.
2. Remove wire tie (6) securing the cable to the vertical support (Figure 16-117, Page 16-50).
3. Using a pair of pliers, apply pressure to the locking tabs of the cable end (1) where it attaches to the dif-
ferential lock handle mounting bracket (Figure 16-13, Page 16-8).
4. While maintaining pressure on the locking tabs, pull the differential lock cable toward the rear of the
vehicle to disconnect the cable from the bracket (Figure 16-13, Page 16-8).
5. With the cable disconnected from the bracket, rotate the cable connector toward the driver side of the
vehicle to disconnect the cable from the differential lock lever (1) (Figure 16-14, Page 16-9).
