Transfer Case Inspection

TRANSFER ASSEMBLY

INSPECTION
1. INSPECT CENTER DIFFERENTIAL CARRIER ASSEMBLY





a) Using a feeler gauge, measure the center differential carrier pinion gear thrust clearance.
Standard clearance: 0.2 to 0.5 mm (0.008 to 0.020 inch)
If the clearance is greater than the standard clearance, replace the center differential carrier.

2. INSPECT CENTER DIFFERENTIAL CLUTCH DISC SET





a) Check whether the sliding surfaces of the disc and flange are worn or burnt. If necessary, replace them.

NOTICE:
^ If the lining of the disc is peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

3. INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY





a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 15.2 to 15.8 mm (0.5984 to 0.6220 inch)
If the free length is shorter than the standard free length, replace the transfer direct clutch return spring.

4. INSPECT TRANSFER DIRECT CLUTCH DRUM





a) Using a cylinder gauge, measure the inside diameter of the transfer direct clutch drum.
Standard inside diameter: 65.00 to 65.06 mm (2.559 to 2.564 inch)
If the inside diameter is greater than the standard inside diameter, replace the transfer direct clutch drum.

5. INSPECT TRANSFER CENTER SUPPORT





a) Using a cylinder gauge, measure the inside diameter of the transfer center support.
Standard inside diameter: 49.9 to 50.1 mm (1.965 to 1.972 inch)
If the inside diameter is greater than the standard inside diameter, replace the transfer center support.