Transfer Case: Adjustments

Fig. 10 Transfer Case Backlash Adjustment:

A growling noise from the transaxle that gets louder as vehicle speed increases may be caused by an incorrect transfer case backlash setting.

Models PMA-BX Through PMA-BX10 Transfer Cases

1. Remove transfer case and discard gasket.
2. Clean gasket surface, then install a new gasket (part No. E83Z-7Z168-A).
3. Install transfer case to transaxle and torque all 13 attaching bolts to 12-15 ft. lbs.
4. Remove cup plug and secure backlash measuring gauge through opening, Fig. 10. Tighten wing nut on back of tool.
5. With transaxle in Park position, remove one bolt from transfer case, then install a rod on transaxle panrail.
6. Secure dial indicator to rod, Fig. 10, then rotate both front wheels until park gear is wedged tightly against park pawl.
7. Position stylus of dial indicator on end of backlash measuring gauge, then push gauge upward to zero the dial indicator.
8. Push down on measuring gauge and read backlash. Maintain load on park gear, park pawl and wheels while reading backlash.
9. Backlash should measure .031-.066 inch.
10. Replace existing gasket with the appropriate new gasket, then recheck backlash:
a. If backlash measures .031 inch or less, install gasket 7A191-K.
b. If backlash measures .066 inch or greater, install gasket 7A191-I.
c. If backlash measures .031-.066 inch, install gasket 7A191-J.

Except Models PMA-BX Through PMA-BX10 Transfer Cases

1. Remove transfer case and discard gasket.
2. Clean gasket surface, then install a new gasket (part No. 7A191-H).
3. Install transfer case to transaxle and torque all 13 attaching bolts to 15-19 ft. lbs.
4. Remove cup plug and secure backlash measuring gauge through opening, Fig. 10. Tighten wing nut on back of tool.
5. With transaxle in Park position, remove one bolt from transfer case, then install a rod on transaxle panrail.
6. Secure dial indicator to rod, Fig. 10, then rotate both front wheels until park gear is wedged tightly against park pawl.
7. Position stylus of dial indicator on end of backlash measuring gauge, then push gauge upward to zero the dial indicator.
8. Push down on measuring gauge and read backlash. Maintain load on park gear, park pawl and wheels while reading backlash.
9. Backlash should measure .012-.047 inch.
10. Replace existing gasket with the appropriate new gasket, then recheck backlash:
a. If backlash measures .012-.047 inch, install gasket 7A191-H.
b. If backlash measures .048-.053 inch, install gasket 7A191-G.
c. If backlash measures .054-.060 inch, install gasket 7A191-F.
d. If backlash measures .061 inch or greater, install gasket 7A191-E.