Transfer Case Assembly

JF3A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: INSPECTION

1. INSPECT TRANSFER INPUT SHAFT

(a) Using a micrometer, measure the diameter of the input shaft journal surface.





Minimum diameter:

68 mm (2.68 in.)

If the diameter is less than the minimum, replace the input shaft.

(b) Using a dial indicator, measure the inside diameter of the input shaft bush.





Maximum inside diameter:

46 mm (1.81 in.)

If the inside diameter is greater than the maximum, replace the input shaft.

2. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY

(a) Using a feeler gauge, measure the thrust clearance of the pinion gear.





Standard clearance:

0.11 to 0.85 mm (0.00434 to 0.0334 in.)

Maximum clearance:

0.85 mm (0.0334 in.)

If the clearance is greater than the maximum, replace the low planetary gear assembly.

3. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY

(a) Using a dial indicator, measure the radial clearance of the pinion gear.





Standard clearance:

0.011 to 0.038 mm (0.000434 to 0.00150 in.)

Maximum clearance:

0.038 mm (0.00150 in.)

If the clearance is greater than the maximum, replace the low planetary gear assembly.

4. INSPECT REAR TRANSFER OUTPUT SHAFT

(a) Using a micrometer, measure the diameter of the output shaft journal.





Minimum Diameter:





If the diameter is less than the minimum, replace the output shaft.

5. INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND FRONT DRIVE CLUTCH SLEEVE

(a) Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.





Maximum clearance:

0.8 mm (0.0315 in.)

If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.

6. INSPECT NO. 2 TRANSFER GEAR SHIFT FORK AND HIGH AND LOW CLUTCH SLEEVE

(a) Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.





Maximum clearance:

3 mm (0.118 in.)

If the clearance is greater than the maximum, replace the clutch sleeve or shift fork.

7. INSPECT NO. 1 SYNCHRONIZER RING

(a) Apply gear oil to the cone of the input shaft, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring. If it can turn, replace the No. 1 synchronizer ring.





(b) Push the No. 1 synchronizer ring to the cone of the input shaft. Measure the clearance between the No. 1 synchronizer ring and input shaft.

Standard Clearance:

0.86 to 1.54 mm (0.0339 to 0.0606 in.)

Minimum Clearance:

0.86 mm (0.0334 in.)

If the clearance is not as specified, replace the No. 1 synchronizer ring with a new one.





8. INSPECT TRANSFER SYNCHRONIZER RING SET

(a) Apply gear oil to the cone of the transfer sprocket sub-assembly, and check that it does not turn in both directions while pushing the transfer synchronizer ring set. If it can turn, replace the transfer synchronizer ring set.





(b) Push the transfer synchronizer ring set to the cone of the transfer sprocket sub-assembly. Measure the clearance between the transfer synchronizer ring set and transfer sprocket sub-assembly.

Standard Clearance:

1.18 to 2.22 mm (0.0465 to 0.0874 in.)

Minimum Clearance:

1.18 mm (0.0465 in.)

If the clearance is not as specified, replace the transfer synchronizer ring set with a new one.