103
4. If clearance is not as specified, repeat steps 1 and 2
using thicker (clearance too great) or thinner (clear-
ance too small) until correct specification is reached.
Assembling Differential Assembly
1. With the pinion gear and new bearings installed,
place the selected (backlash) shim on the gear case
side of the ring gear with the chamfered side toward
the ring gear; then install into gear case/differential
housing.
GC031A
GC059
2. Place the selected (end-play) shim, chamfered side
toward the gear, onto the cover side of the ring gear.
GC059B
NOTE: The spider and ring gear assembly must be
replaced as a complete unit.
3. Making sure the O-ring is properly positioned on the
differential housing cover assembly, install the cover
with existing cap screws (coated with green Loctite
#609). Account for the ID tag. Tighten the cap
screws evenly to 18 ft-lb.
NOTE: Grease can be applied to the O-ring for ease
of assembling.
4. Install the shift fork shaft w/spring into the housing
making sure the shaft O-ring is positioned to the
inside.
CC892
5. Install the shift fork assembly making sure the fork
leg is facing upward. Apply a small amount of oil to
the gasket; then install the gasket.
CC893
6. Place the input shaft housing assembly onto the gear
case housing; then secure with the existing cap
screws. Tighten to 18 ft-lb.
CD103
Содержание XC 450 2016
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