Transfer Case Assembly

VF2BM TRANSFER: TRANSFER ASSEMBLY: INSPECTION

1. INSPECT TRANSFER INPUT SHAFT





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

Minimum diameter:

47.59 mm (1.88 in.)

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

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





Maximum diameter:

39.14 mm (1.54 in.)

If the inside diameter exceeds the maximum, replace the input shaft.

2. INSPECT SYNCHRONIZER RING





(a) Turn the ring and confirm that the input shaft and synchronizer ring are engaged with each other.

(b) Using a feeler gauge, measure the clearance between the synchronizer ring and the input shaft spline.





Standard clearance:

1.05 to 1.85 mm (0.0413 to 0.0728 in.)

Minimum clearance:

0.80 mm (0.0315 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

3. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE





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

Standard clearance:

0.11 to 0.84 mm (0.0043 to 0.0331 in.)

Maximum clearance:

0.84 mm (0.0331 in.)

If the clearance exceeds the maximum, replace the planetary gear assembly.

4. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE





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

Standard clearance:

0.009 to 0.038 mm (0.00035 to 0.00150 in.)

Maximum clearance:

0.038 mm (0.00150 in.)

If the clearance exceeds the maximum, replace the planetary gear assembly.

5. INSPECT TRANSFER REAR OUTPUT SHAFT





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

Minimum diameter:

27.98 mm (1.102 in.) for part A

36.98 mm (1.456 in.) for part B

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

6. INSPECT DRIVE SPROCKET RADIAL CLEARANCE





(a) Using a dial indicator, measure the radial clearance between the sprocket and the shaft with the needle roller bearing installed.

Standard clearance:

0.010 to 0.055 mm (0.00039 to 0.00217 in.)

Maximum clearance:

0.055 mm (0.00217 in.)

If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft and drive sprocket bearing.

7. INSPECT GEAR SHIFT FORK NO. 1 AND HUB SLEEVE CLEARANCE





(a) Using a feeler gauge, measure the clearance between the gear shift fork No. 1 and drive clutch sleeve.

Maximum clearance:

1.0 mm (0.0394 in.)

If the clearance exceeds the maximum, replace the gear shift fork No. 1 and drive clutch sleeve.

8. INSPECT GEAR SHIFT FORK NO. 2 AND HUB SLEEVE CLEARANCE





(a) Using a feeler gauge, measure the clearance between the gear shift fork No. 2 and high and low clutch sleeve.

Maximum clearance:

1.0 mm (0.0394 in.)

If the clearance exceeds the maximum, replace the gear shift fork No. 2 and high and low clutch sleeve.