Inspection

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Shift Arm Thickness:

SHIFT ARM THICKNESS
Use a micrometer to measure the shift arm thickness. If the measured value is less than the specified limit, the shift arm must be replaced.






DETENT SPRING FREE LENGTH
Use a veinier caliper to measure the detent spring free length. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent Spring Length:
Standard: 26.8 (1.06) mm(in)
Limit: 26.2 (1.03) mm(in)






DETENT SPRING TENSION
Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the valve spring must be replaced.
Valve Spring Tension
Compressed Height: 20 mm (0.787)
Standard: 8.9-9.9 (19.6-21.8/87.2-213.6) kg(lb/N)






BLOCK RING AND DOG TEETH CLEARANCE
Use a thickness gauge to measure the clearance between the block ring and the dog teeth. If the measured value exceeds the specified limit, the block ring must be replaced.
Block Ring and Dog Teeth Clearance
Standard: 1.5 (0.059) mm(in)
Limit: 0.8 (0.032) mm(in)

Block Ring And Insert Clearance:

BLOCK RING AND INSERT CLEARANCE
Use a vernier caliper or thickness gauge to measure the clearance between the block ring and the insert. If the measured value exceeds the specified limit, the block ring and the insert must be replaced.











CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the clutch hub and the insert. If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.






MAINSHAFT RUN-OUT
1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central portion run-out. If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.
Mainshaft Run-Out
Limit: 0.05 (0.0019) mm(in)

Gear Inside Diameter:

GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside diameter. If the measured value is less than the specified limit, the gear must be replaced.






REVERSE IDLER GEAR AND IDLER GEAR SHAFT CLEARANCE
1. Use a micrometer to measure the idler gear shaft diameter.
2. Use an inside dial indicator to measure the idler gear inside diameter.
3. Calculate the idler gear and idler gear shaft clearance. Idler gear inside diameter - idler gear shaft diameter = idler gear and idler gear shaft clearance. If the measured value exceeds the specified limit, the idler gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearence
Standard: 0.041-0.074 (0.0016-0.0029) mm(in)
Limit: 0.150 (0.0059) mm(in)

Clutch Hub Spline Play:

CLUTCH HUB SPLINE PLAY
1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. It the measured value exceeds the specified limit, the clutch hub must be replaced.






BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 (0.068) mm(in)

FRONT COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.






Oil Seal Installation
1. Use the oil seal installer to install the oil seal to the front cover.
Oil Seal Installer J-26540
2. Apply gear oil to the oil seal lip.

REAR COVER OIL SEAL
Oil Seal Replacement
Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.






Oil Seal Installation
1. Use the oil seal installer to install the oil seal to the rear cover.
Oil Seal Installer J-29769
2. Apply engine oil to the oil seal lip.

TRANSFER CASE Service and Repair