Product Instruction Manual
3
DISASSEMBLING THE ACTUATOR
Disassembling Actuators with clamping and Non-
clamping Lever Arm If it is necessary to
disassemble an actuator with a non-clamping
lever arm, refer to Figures 1 and 2, and proceed
as follows:
1. Depressurize actuator and disconnect all
tubing.
2. Relieve the spring compression by removing
the adjusting screw.
WARNING
: Spring is under
compression.
3. Using a screwdriver, remove the retaining
ring from the groove at the base of the
cylinder.
4. Pull the cylinder off the transfer case and
piston.
Note:
Substantial O-ring resistance may
be felt.
WARNING:
Do not use air
pressure to remove cylinder.
5. Remove spring button and spring.
CAUTION:
Care must be taken not
to damage the sliding seal
assembly or actuator stem O-ring
when removing the actuator stem.
6. Remove the actuator stem locknut. The
piston and piston stem O-ring may now be
removed from the actuator stem.
7. Remove the spiral snap-ring holding the
sliding seal assembly in place.
8. Remove the retaining washer and sliding
seal collar. These components can usually
be removed by hand or by gently prying the
outside surface of the collar upward.
WARNING:
Do not scratch the
bottom surface of the sliding seal
collar with a screwdriver or
sharp object. Scratches can cause
excessive wear and possible
leakage.
9. Remove the transfer case cover plate by
removing the four bolts.
10. Remove the yoke from the transfer case by
removing the four lug bolts.
11. Remove the pivot pin from the non-clamping
lever arm by removing a retaining ring.
12. The actuator stem can now be easily
removed from the transfer case.
13. The non-clamping lever arm can be removed
by first removing the positioner according to
the appropriate positioner maintenance
bulletin.
14. If the yoke/cover plate bearings need to be
replaced, press them out of the yoke and/or
cover plate using a press and arbor.
15. The non-clamping lever arm bearings can be
replaced by pressing them out with a press
and arbor.
REASSEMBLING THE ACTUATOR
To reassemble an actuator with a non-clamping
lever arm, refer to Figures 1 and 2, and proceed
as follows:
1. Clean and lubricate all internal parts. All O-
rings should be replaced and lubricated
using a silicone lubricant (Dow Corning 55M
or equivalent). The bore that houses the
sliding seal assembly in the transfer case
must be smooth and clean.
2. If lever arm bearings were removed, install
new bearings by pressing them into place
with a press and arbor.
3. Install lever arm into transfer case through
cover plate/yoke openings.
4. Slide actuator stem through the top opening
of transfer case and connect to the lever arm
with the pivot pin and two retaining rings.
5.
If the yoke/cover plate bearings were
removed, press new bearings into the yoke
and cover plate using a press and arbor.
6. On clamping lever design, firmly tighten
clamp bolt on clamping lever arm actuators.
