Inspection

Transfer Assembly Inspection

Transfer Assembly Disassembly and Reassembly:Motor-Shift Type (Transfer with Shift Actuator)

- Check needle bearing and bearing contacting surface for damage. Replace as required.
- Check gear tooth surface and shift mechanism in the same manner as with transmission. Correct or replace as necessary.
- Check drive chain and sprockets for abnormal wear or damage. Replace as required.
- Check transfer control cover assembly for abnormal wear or damage. Replace control cover assembly.
- Assemble input gear assembly (4), center differential assembly (2), low gear (3) and reduction shift sleeve (1), check whether reduction shift sleeve moves smoothly, and replace it if defect is found.





- Measure the width of groove part of reduction shift sleeve (1).
If measured value is out of specification, replace reduction sleeve.

Reduction shift sleeve groove width
: 6.9 - 7.1 mm (0.272 - 0.280 in.)





- Assemble front drive clutch hub (2), front drive sprocket (3) and differential lock clutch sleeve (1), check whether differential lock clutch sleeve moves smoothly, and replace it if defect is found.





- Measure the width of groove part of differential lock clutch sleeve (1).
If measured value is out of specification, replace reduction sleeve.

Differential lock clutch sleeve groove width
: 6.9 - 7.1 mm (0.272 - 0.280 in.)





- Measure thickness of shift fork. If thickness of shift fork is out of specification, replace control cover assembly.

Shift fork thickness
: 6.5 - 6.8 mm (0.256 - 0.268 in.)






- Check 4L/N switch and center differential lock switch for continuity between "a" and "b" terminals of switch. If check result is not as specified below, replace switch.

4L/N switch and center differential lock switch specification
Switch button (1) released: Continuity
Switch button (1) kept pushing: No continuity





- Connect terminal "1" of transfer actuator (3) to the positive of battery (4) and terminal "4" to the negative, and confirm cam (2) rotates in the direction of A. At the same time, connect terminal "4" of transfer actuator (3) to the positive and terminal "1" to the negative, and confirm it rotates in the direction of B. If it does not operate correctly, replace transfer actuator assembly.

NOTE:
- Do not rotate transfer actuator applying voltage, while transfer actuator removed from transfer control cover assembly (1).
- Do not apply voltage of the battery in the direction of rotation limit at rotation limit position of transfer actuator.





- Operate the motor, and measure the resistance between following terminals of transfer actuator when matching transfer actuator (1) to 4H-lock position and 4L-lock position.
If measured value is out of specification, replace transfer actuator.

Transfer actuator resistance