Transfer Case: Testing and Inspection
Transfer Assembly Inspection1. Raise the vehicle, and make sure it is supported securely.
2. Shift the transmission into the E1 position.
3. Make a reference mark (A) across the propeller shaft (B) and the transfer companion flange (C).
4. Separate the propeller shaft from the transfer.
5. Set a dial indicator (A) on the transfer companion flange (B); position dial indicator tip (C) on the direct extension of the bolt hole center (D).
6. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.02 - 0.06 inch)
7. If the measurement is out of standard, remove the transfer assembly, and adjust the transfer gear backlash.
8. Check for fluid leaks between the mating faces of the transfer assembly and transmission.
9. If there is a leak, remove the transfer assembly, and replace the O-ring. Also check for fluid leaks between the mating faces of the transfer housing and transfer cover. If there is a leak, remove the transfer cover, and replace the O-ring.
10. Check for leaks between the transfer companion flange and transfer oil seal.
11. If there is a leak, remove the transfer assembly from the transmission, and replace the transfer oil seal and O-ring on the transfer output shaft (hypoid gear). If oil seal and O-ring replacement is required, you will need to check and adjust the transfer gear tooth contact, transfer gear backlash, the tapered roller bearing starting torque, and the total starting torque. Do not replace the oil seal with the transfer assembly on the transmission.