Transfer Case Actuator: Service and Repair

Fig. 5 Axle vacuum motor & shift fork assembly:

Fig. 6 Removal & installation of shift fork assembly:

1983-87 MODELS WITH SELEC-TRAC

REMOVAL

1. Raise and support front of vehicle, then drain lubricant from front axle.
2. Disconnect vacuum lines from shift motor.
3. Remove axle housing cover, shift motor and shift fork as an assembly.

DISASSEMBLY

1. Remove shift fork to pivot pin retaining E-clip.
2. Disconnect shift fork pivot from shift motor shaft by threading pivot out of shaft.
3. Remove shift fork assembly from pivot pin.
4. Remove shift motor retaining nut and remove shift motor from axle housing cover.
5. Remove O-ring from shift motor.

ASSEMBLY

1. Install new O-ring on motor.
2. Apply small amount of sealer around shift motor mounting hole and install shift motor and retaining nut.
3. Install shift fork assembly on pivot pin and thread shift fork pivot into shift motor shaft. Install E-clip on shift fork pivot pin.



INSTALLATION

1. Apply RTV sealant to axle cover sealing surfaces and install on axle. Shift fork and fork tabs must be engaged in shift collar before installing cover bolts.
2. Torque axle housing cover bolts to 20 ft. lbs. Fill axle to bottom of fill plug hole with suitable gear lubricant and reconnect vacuum lines.