Technical Library

Installation

Please see below instructions and photos of a 1.2 gear set being fitted, please note it is the same process for the 1.003 gears:

1) you should have these parts :

2) remove sump,

3) remove hi/lo housing

4) remove the 8 bolts holding the front housing on,

5) remove 30mm intermediate pin nut

6) remove pin

7) remove front housing,

8) remove detent screw

9) remove spring and ball,

10) remove diff assembly,

11) remove large nut,

12) press off top bearing,

13) refit low gear and the inner selector hub, note the outer groove goes to the low gear side,

14) before you fit the outer selector hub and new gear pls check the selector collar drops on the gear, sometimes the sharp edges will stp it dropping over the dog teeth like this :

15) if it doesn't drop on just knock it on with a mallet and then it should fit OK,

16) press the gear, top hat and bearing back on,

17) refit nut,

18) when the nut is tight, check the gear spins freely,

19) peen the nut,

20) fit fork to diff

21) knock old bearings out and press into new gear,

22) Clean all faces,

23) refit diff,

24) apply sealant,

25) refit housing,

26) check it spins freely,

27) put sealant on pin head,

28) and hole in casing,

29) and other hole,

30) put gear in with bearings, use rope and rule,

31) lower gear in with the new collapsible spacer between the bearings,

32) push in pin,

33) tighten intermediate nut,

34) you will need to tighten the nut until the spacer collapses, you can feel this as the drag will increase which you will feel if you keep spinning it as you tighten the nut,

35) you should see about 1 thread,

36) apply some oil and check it spins OK,

37) peen the nut,

38) apply sealant,

39) refit sump,

40) apply sealant,

41) refit hi/lo housing,

42) refit ball, spring and plug,