Transfer Case: Testing and Inspection

Transfer Assembly Inspection on Vehicle

1. Raise the vehicle on a lift, and make sure it is supported securely.

2. Shift the transmission into neutral.

3. Make reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C).






4. Separate the No. 1 propeller shaft from the transfer companion flange.

5. Set a dial indicator (A) on the transfer companion flange (B); position the dial indicator tip (C) on the top of the bolt (D).





6. Measure the transfer gear backlash.

Standard: 0.06-0.16 mm (0.0024-0.0063 in)

7. If the backlash is out of the standard, remove and disassemble the transfer assembly, and adjust the transfer gear backlash Transfer Assembly Reassembly (M/T).

8. Check for fluid leaks between the mating surfaces of the transfer assembly and the transmission.

9. If there is a leak, remove the transfer assembly, remove the transfer cover, and replace the O-ring.

10. Check for fluid leaks between the transfer companion flange and the transfer oil seal.

11. If there is a leak, remove the transfer assembly from the transmission, and replace the transfer oil seal and the O-ring on the transfer output shaft (hypoid gear). If an oil seal and O-ring replacement is required, you will need to check and adjust the transfer gear tooth contact, the transfer gear backlash, the tapered roller bearing starting torque, and the total starting torque Transfer Assembly Reassembly (M/T). Do not replace the oil seal with the transfer assembly on the transmission.