Tracker Off-Road 800SX Service Manual page 143

GC014
3. Lubricate the input shaft with High-Performance #2
Molybdenum Disulfide Grease packing the splines;
then assemble allowing excess grease to freely
escape. Grease the pinion housing seal; then install
the input shaft into the pinion housing and secure
with a new snap ring.
NOTE: Any time drive splines are separated, clean

all splines with parts-cleaning solvent and dry with
compressed air; then lubricate with recommended
grease.
GC009A
4. With the return spring over the shuttle shaft, place
the shuttle shaft with O-ring into the differential
housing.
XR352A
XR354
5. Place the dowel pin into the differential housing;
then install a new gasket. Place the coupler onto the
shift fork; then simultaneously engage the shift fork
to the shuttle shaft and the internal splines of the cou-
pler to the splines of the pinion gear shaft; then ver-
ify the shift fork moves freely from 4WD to 2WD to
4WD by pushing down on the shift fork shaft and
then releasing.
MOD357
MOD358
6. Align the splines of the output shaft to the internal
splines of the coupler; then place the pinion housing
onto the differential housing; then place the drive
actuator bracket (A) into position; then secure the
assembly with three cap screws and tighten to 22 ft-lb
(29.9 N-m) (existing) or 28 ft-lb (38.1 N-m) (new
differential housing).
141