Diaphragm Cylinder

DIAPHRAGM CYLINDER

COMPONENTS






DISASSEMBLY OF DIAPHRAGM CYLINDER




1. REMOVE DIAPHRAGM CYLINDER ASSEMBLY
(a) Remove the diaphragm cylinder assembly from the diaphragm cylinder body.
(b) Remove the gasket.




2. REMOVE SHIFT LINK LEVER AND STRAIGHT PIN




3. REMOVE SHOE FROM SHIFT LINK LEVER
Using a pin punch and hammer, remove the two shoes from the shift link lever.




4. REMOVE DIAPHRAGM CYLINDER BODY
(a) Remove the diaphragm cylinder body from the transfer case.
(b) Remove the gasket.




5. INSPECT DIAPHRAGM CYLINDER ASSEMBLY
(a) With at least 400 mmHg (15.75 in.Hg, 53.3 kpa) of vacuum in the diaphragm, confirm that the shaft moves.
Standard stroke: 22 mm (0.87 in.)
(b) Confirm again on the diaphragm side.
(c) With at least 400 mmHg (15.75 in. Hg, 53.3 kPa) of vacuum in the diaphragm, confirm the gauge needle is stable.




6. REMOVE SUCTION TUBE
(a) Remove the suction tube from the diaphragm cylinder body cover.
(b) Remove the gasket.




7. REMOVE DIAPHRAGM CYLINDER BODY COVER




8. REMOVE FOLLOWING PARTS FROM DIAPHRAGM PUSH ROD
- Two washers
- Two plates
- Diaphragm
- 0-ring



INSPECTION OF DIAPHRAGM CYLINDER COMPONENTS




IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, remove the oil seal.




(b) Using a socket wrench, drive in a new oil seal.
(c) Apply MP grease to the oil seal lip.



ASSEMBLY OF DIAPHRAGM CYLINDER




1. INSTALL FOLLOWING PARTS TO DIAPHRAGM PUSH ROD
- Two washers
- Two plates
- Diaphragm
- 0-ring




2. TORQUE DIAPHRAGM PUSH ROD NUT
Torque: 375 kg-cm (27 ft-lb, 37 Nm)




3. INSTALL DIAPHRAGM PUSH ROD INTO DIAPHRAGM CYLINDER COVER
4. INSTALL DIAPHRAGM CYLINDER BODY COVER
Install the diaphragm cylinder body cover to the diaphragm cylinder cover.
Torque the bolts.
Torque: 75 kg-cm (65 in.-lb, 7.4 Nm)




5. INSTALL SUCTION TUBE
Torque: 375 kg-cm (27 ft-lb, 37 Nm)




6. INSTALL DIAPHRAGM CYLINDER BODY
Install the diaphragm cylinder body with a new gasket to the transfer case.
Torque the bolts.
Torque: 185 kg-cm (13 ft-lb, 18 Nm)




7. INSTALL SHOE TO SHIFT LINK LEVER
Using a press, install two shoes to shift link lever.




8. INSTALL SHIFT LINK LEVER AND STRAIGHT PIN
(a) Apply MP grease to shoe and straight pin.
(b) Install the shift link lever and straight pin.




9. INSTALL DIAPHRAGM CYLINDER ASSEMBLY
Install the diaphragm cylinder assembly with a new gasket to the diaphragm cylinder body.
Torque the bolts.
Torque: 185 kg-cm (13 ft-lb, 18 Nm)