Differential Lock System; Differential Lock System Inspection; Differential Lock Cable Removal - Pioneer 1200 Maintenance Service Manual

16
MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Forward/Reverse Shifter Cable Adjustment, Continued:
∆
CAUTION
• Be sure threads of cable are engaged in ball joint socket at least 1/4-inch (6.35 mm). If ball
joint socket comes loose from the cable, the Forward/Reverse shifter will not operate properly.
For major adjustments, the cable retaining nuts (5) must be loosened and adjusted. When the cable is prop-
erly adjusted, with the Forward/Reverse handle (9) (Figure 16-62, Page 16-25) in the NEUTRAL position, the
shifter lever of the transaxle will also be in the NEUTRAL position (Figure 16-61, Page 16-24). Retighten nuts
to 22 ft-lb (29.8 N·m).

DIFFERENTIAL LOCK SYSTEM

See General Warning, Section 1, Page 1-1.
If the differential lock cable is damaged in any way, it must be replaced. See following WARNING.
∆
WARNING
• If for any reason the differential lock system is not operating correctly, the system must be
repaired or replaced before attempting to operate the vehicle. With the differential lock
engaged, vehicle turning functions are greatly reduced. Failure to heed this warning could
result in loss of vehicle control and severe personal injury.

DIFFERENTIAL LOCK SYSTEM INSPECTION

The differential lock system should periodically be inspected for proper operation.
1. Place chocks at the front wheels, lift the rear of the vehicle with a floor jack and place jack stands under
the axle tubes to support the vehicle. See WARNING "Lift only one end of the vehicle..." in General
Warning, Section 1, Page 1-1.
2. With the differential lock handle in the forward position (unlocked), rotate one of the rear wheels by hand.
The wheel should be fairly easy to rotate and the other rear wheel should rotate in the opposite direction,
indicating that the differential lock is not engaged. If this is not the case, the differential handle, cable or
housing must be repaired or replaced before attempting to drive the vehicle.
3. With the wheels at rest, pull the differential lock handle toward the rear of the vehicle (locked position).
Observe the cable end and differential lock arm on the differential lock housing. The cable should move
freely when the handle is moved. Initially, there may be slack in the cable at the differential housing. Rota-
tion of the rear tire will eliminate this slack when the differential lock is fully engaged.
4. With the differential lock handle in the rear position (locked), rotate one of the rear wheels by hand. The
wheel should be harder to rotate than in the unlocked position and the other rear wheel should rotate in
the same direction, indicating that the differential lock is engaged. If this is not the case, the differential
handle, cable or housing must be repaired or replaced before attempting to drive the vehicle.

DIFFERENTIAL LOCK CABLE REMOVAL

1. Place the differential lock handle in the unlocked position.
2. Remove wire tie (6) securing the cable to the vertical support (Figure 16-63, Page 16-28).
Page 16-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Differential Lock System