Lever was getting impossible to move, using a 500mm socket extension on the lever was still a big effort, rebuild time. Seems like a common problem on most part time 80 & 7X's with the HF1A, couldn't find any threads about rebuilds for part time levers. Don't have photo's of everything but it's a simple enough explanation.
Remove carpet, shifter surround etc. Remove the four 12mm bolts securing transfer lever to transmission. There are four rubber cones and a rubber gasket, put them aside somewhere safe.
No photos of this part. Remove the circlip and spring on the underside of the lever, this is for returning the lever down after lifting to get into N & L4. Remove the small dowel passing through the handle & the main shaft. Photo's the holes in photos below. Liberal spray of penetrating oil and leave it alone for about a beer or two.
The grease inside the assembly has solidified and nothing want's to move, do NOT smack anything with force, it'll bend things before the shaft moves. Use a flat blade screwdriver or similar to gently pry between the nylon washer and the body of the unit. Takes time, but it'll come out slowly. You should be left with this. Give everything a good clean, remove the old grease and any corrosion.
Grease everything up and reassemble.
The lever is notched for the main shaft to pass thru', refer pics 2 & 3. The spring & circlip mentioned earlier go on the end of this.
Insert shaft into the body, ensure the hole for the dowel is facing upwards and the small leg that attaches the rod from the transfer is facing down. There is another nylon washer that should be put on the shaft now before the lever.
No photos but there is a plate that needs to be installed onto the lever now, lines up the the three holes you see on the body. This was just a test fit at this point. Insert the lever & pass the shaft through the lever. This is all splined, it'll only go in one way, can't get it wrong. The washer is missing in this photo, it should be between the lever and body on the right side.
Install everything back onto the transmission, don't forget those cones and the gasket.
Lever now moves easily, too easily even. It's actually difficult to engage neutral now without flying forward into H4, but that's a better problem than being stuck in low.
Remove carpet, shifter surround etc. Remove the four 12mm bolts securing transfer lever to transmission. There are four rubber cones and a rubber gasket, put them aside somewhere safe.
No photos of this part. Remove the circlip and spring on the underside of the lever, this is for returning the lever down after lifting to get into N & L4. Remove the small dowel passing through the handle & the main shaft. Photo's the holes in photos below. Liberal spray of penetrating oil and leave it alone for about a beer or two.
The grease inside the assembly has solidified and nothing want's to move, do NOT smack anything with force, it'll bend things before the shaft moves. Use a flat blade screwdriver or similar to gently pry between the nylon washer and the body of the unit. Takes time, but it'll come out slowly. You should be left with this. Give everything a good clean, remove the old grease and any corrosion.
Grease everything up and reassemble.
The lever is notched for the main shaft to pass thru', refer pics 2 & 3. The spring & circlip mentioned earlier go on the end of this.
Insert shaft into the body, ensure the hole for the dowel is facing upwards and the small leg that attaches the rod from the transfer is facing down. There is another nylon washer that should be put on the shaft now before the lever.
No photos but there is a plate that needs to be installed onto the lever now, lines up the the three holes you see on the body. This was just a test fit at this point. Insert the lever & pass the shaft through the lever. This is all splined, it'll only go in one way, can't get it wrong. The washer is missing in this photo, it should be between the lever and body on the right side.
Install everything back onto the transmission, don't forget those cones and the gasket.
Lever now moves easily, too easily even. It's actually difficult to engage neutral now without flying forward into H4, but that's a better problem than being stuck in low.
