Drive System; Front Drive Actuator - Tracker Off-Road 500S Service Manual

Drive System

GENERAL INFORMATION
Gear cases are 3.6:1.
 NOTE: Never reuse a lock nut. Once a lock nut has
been removed, it must be replaced with a new lock
nut.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: When indicated for use, each special tool

will be identified by its specific name, as shown in the
chart below, and capitalized.
Description
Backlash Measuring Tool (24-Spline Axle)
CV Boot Clamp Tool
Internal Hex Socket
Pinion Gear/Shaft Removal Tool
Gear Case Seal Installer Tool
Hub Retaining Wrench
 NOTE: Special tools are available from the Service
Department.

Front Drive Actuator

 NOTE: The actuator is only serviceable as an
assembly.
 NOTE: The actuator will operate only when the
ignition switch is in the ON position.
The front drive actuator is located on the right side of the
front differential input housing. With the engine stopped
and the ignition switch in the ON position, a momentary
"whirring" sound can be heard each time the drive select
switch is shifted. If no sound is heard, see Electrical Sys-
tem. If the actuator runs constantly or makes squealing or
grinding sounds, the actuator must be replaced.
REMOVING
1. Turn the ignition switch to the ON position; then
select 2WD LOCK on the drive select switch.
Remove the drain plug from the bottom of the differ-
ential and allow the fluid to drain; then remove the
seat and center floorboard kick panel.
2. Remove the air box and intake tube found below the
center floorboard kick panel.
118
PK305
3. From the rear, remove the two cap screws securing
the actuator to the differential and bracket.
p/n
0544-010
Common Tool
Common Tool
Common Tool
0444-273
0444-270
PK306A
4. Remove the rubber access plug found toward the
back side of the actuator; then remove the selector
shaft circlip and spacer. Discard the circlip.
PK034A
PK035