SPECIAL TOOLS Drive System A number of special tools must be available to the technician when performing service procedures in this section. NOTE: Some photographs and illustrations used in this section are used for clarity purposes Description p/n only and are not designed to depict actual CV Boot Clamp Tool conditions. Internal Hex Socket NOTE: Critical torque specifications are Pinion Gear/Shaft Removal Tool located in Section 1. Slide Hammer Kit NOTE: Specifications regarding the gear cases Gear Case Seal Installer Tool E014 (capacities, lubricant type, etc.) can be found in Section 1 of this manual. NOTE: Special tools are available from the KYMCO Service Parts Department. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) Front Drive Actuator GENERAL INFORMATION All gear cases are tagged beneath a cover bolt. This tag NOTE: The actuator is not a serviceable compo- is marked with a production date code, sequence code, nent. If it is defective, it must be replaced. and a ratio code. The "1" or "3.1" on the lower-right corner indicates a NOTE: The actuator will operate only when the 3.1:1 gear set ratio (11:34 teeth). ignition switch is in the ON position. The die-cast aluminum housings have been assembled The front drive actuator is located on the side of the with thread-rolling screws (trilobular). When assem- front drive input housing. With the engine stopped and bling with these screws, start the screws carefully into the ignition switch in the ON position, a momentary the housing; then use the following torque values. "whirring" sound can be heard each time the front drive selector switch is shifted. If no sound is heard, New Reassembled see Section 5. If the actuator runs constantly or makes Size Housing Housing squealing or grinding sounds, the actuator must be replaced. M6 (Torx T-30 Recess) 8-9.5 ft-lb 6.5-9 ft-lb REMOVING M8 (Torx T-40 Recess) 25-31 ft-lb 21-25 ft-lb M10 (Torx T-50 Recess) 37-45.5 ft-lb 31-38 ft-lb 1. Disconnect the connector on the actuator harness. 2. Remove the mounting cap screw from the drive- shaft side of the actuator. KC293A 6-2 3. Remove the mounting cap screw from below the actuator on the suspension side.