Shift Box Relocation
The “Shift box” (the rectangular box on the side of the otherwise cylindrical Klune) can be located in any of three locations on the Klune. The other possible locations are covered with inspection covers. We have standard tables that we use to determine where to put the box depending on the application, however due to variables in individual installations, it turns out for one reason or another the shift box would be better of in one of the other two possible locations. This is no big deal, and if performed competently, will not void your warranty.
1) Mark a line with a “sharpie” pen or other across the dividing seam between the two case halves. In this manner, you will know the correct rotational clocking of the case halves when you put them back together again.
2) Remove the 6 bolts holding the 2 case halves together
3) Separate the 2 case halves. There are pry points located around the separation of the 2 halves for this purpose. It will be “glued” together by the RTV sealant, and may be stubborn. It is possible to inset a narrow chisel on the separation line inside the pry opening. Tap the chisel into the seam using a hammer to separate the case halves if necessary.
4) Remove the plugs (or vent barb) from either side of the shift box. Do NOT remove the detent mechanism (the one with the outer nut on it). This will allow access to remove the shift fork: Using a drift, tap out the roll pin that retains the shift fork to the shift rod. Pull the shift rod out of the box enough to free up the shift fork. (It is best not to pull it out all the way, as to get it back in you will have to re-install and re-adjust the detent mechanism). Remove the shift fork and range sleeve from the case half.
5) Remove the four bolts retaining the inspection cover where you want the box to go, and remove the four bolts holding the shift box to the main case. Bolt these back on where you want them (Note: The shift rod must exit to the FRONT of the unit. You cannot turn it around, the detents won’t line up)
6) Put the shift fork back and range sleeve in (the side of the shift fork sleeve where the roll pin fits goes toward the REAR of the unit) (The range sleeve teeth are toward the FRONT of the unit) push the shift rod back through the shift fork, and tap the roll pin back in.
7) Clean off excess dried RTV off the case halves.
8) Using fresh RTV sealant to prevent leakage, bolt the two halves back together in the original alignment. (Using the mark you made in step one)