Outline of Inspection and Repair Procedure

The following describes the inspection and repair procedure for transfer case oil volume and oil leakage from the propeller shaft sleeve yoke plug. Refer to the PROCEDURE section of this bulletin for repair details.

1. Test drive the vehicle and listen for any abnormal grinding or dragging noise from the transfer case. Ignore normal gear noises such as a high pitched whine.

a. If no noise is heard, go to Step 2 (1998 models) or Step 3 (1997 models).

b. If noise is heard, perform the following:
(1) For 1998 models, remove the transfer case and partially disassemble it to inspect for bearing damage, unsmooth gear rotation, or end play. If any are found, replace the transfer case. If none are found, install the transfer case repair kit listed in the PARTS INFORMATION section of this bulletin. Then replace the sleeve yoke.

(2) For 1997 and earlier models, first check for evidence of oil leakage from the sleeve yoke. Then remove the transfer case and partially disassemble it to inspect for bearing damage, unsmooth gear rotation, or end play. If any are found, replace the transfer case. If none are found, install the transfer case repair kit listed in the PARTS INFORMATION section of this bulletin. Then, if evidence of oil leakage from the sleeve yoke was found, replace the sleeve yoke.

2. For 1998 models, replace the sleeve yoke with the repair kit listed in the PARTS INFORMATION section of this bulletin. If no abnormal grinding or dragging noise was heard during the test drive and no oil or only a few drops of oil comes out of the transfer case drain hole, repair the transfer case using the transfer case repair kit listed in the PARTS INFORMATION section of this bulletin. If bearing damage, unsmooth gear rotation, or end play are discovered during repair, replace the transfer case.

3. For 1997 and earlier models, determine whether or not to replace the sleeve yoke and/or repair the transfer case based on the amount of oil drained from the transfer case. If bearing damage, unsmooth gear rotation, or end play are discovered during the repair, replace the transfer case.

PROCEDURE

IMPORTANT:
Before starting this procedure, CHECK ON THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

1. Test drive the vehicle and listen for abnormal grinding or dragging noise from the transfer case. Ignore normal gear noises such as a high pitched whine.

a. If noise is not heard, go to Step 2.

b. If noise is heard:
(1) For 1998 models, go to Step 18 for transfer case repair instructions. Then replace the sleeve yoke as described in Step 7.

(2) For 1997 and earlier models, go to Step 6 to check for evidence of oil leakage from the sleeve yoke. Then go to Step 18 for transfer case repair instructions.

2. Check the model year of the vehicle.

a. If the vehicle is 1997 model year or earlier, go to Step 3.

b. If the vehicle is 1998 model year, go to Step 4.





3. A special gauge was provided to each dealer with the original recall bulletin SR-98-002 (issued April, 1998).

If necessary, a gauge can be created with wire, shaping it to the dimensions shown. Paint the end white so the oil level can be checked after inserting it into the transfer case oil filler hole.





Lift the vehicle on a hoist and check the transfer case oil level by inserting the special gauge into the oil filler hole, then removing it.

a. If oil remains on the gauge, go to Step 6.

b. If no oil remains on the gauge, go to Step 4.





4. Remove the transfer case drain plug.

NOTE:
Oil will drain out taster if the filler plug is also removed.

5. Check whether any oil comes out of the transfer case.

a. If no oil or only a few drops of oil come out, transfer case repair in Step 18 is required. Then go to Step 6.

b. If oil continuously drips out, reinstall the drain plug and go to Step 6.

6. Inspect for oil leaks from the transfer case and sleeve yoke. Check for oil spots on the exhaust pipe around the sleeve yoke. Also check for oil stains or evidence of seepage around the sleeve yoke plug.

IMPORTANT FOR ALL MODELS:
If no oil was found in the transfer case, the transfer case must be repaired as described in Step 18 before this campaign procedure is complete.





a. For 1997 and earlier models, perform each step as necessary:
^ If oil leakage from the sleeve yoke is found, go to Step 7 for sleeve yoke replacement.
^ If there is evidence of leakage from sources other than the sleeve yoke (i.e., input shaft seal, rear oil seal, etc.), replace any damaged parts to repair the leak. Then go to Step 16.
^ If no oil leakage is found, go to Step 16.
^ If abnormal grinding or dragging noise from the transfer case was heard during the test drive, go to Step 18 for transfer case repair instructions.





b. For 1998 models, perform each step as necessary:
^ If no oil leakage is found, go to Step 7 for sleeve yoke replacement.
^ If there is evidence of leakage from sources other than the sleeve yoke (i.e., input shaft seal, rear oil seal, etc.), replace any damaged parts to repair the leak. Then go to Step 7 for sleeve yoke replacement.
^ If abnormal grinding or dragging noise from the transfer case was heard during the test drive, go to Step 18 for transfer case repair instructions.

YOKE REPLACEMENT





7. Make mating marks on the propeller shaft and the rear differential.





8. To prevent scratching or other damage, insert a cloth into each of the propeller shaft joint boots.





9. Remove the propeller shaft as described in Group 25 of the appropriate service manual.





10. Remove the snap rings on the propeller shaft side.





11. Using Special Toot MB990840 or equivalent or a hydraulic press, push the bearing and remove the bearing cap on one side. Then place the tool on the opposite side and push the U-joint and remove the remaining bearing cap.

NOTE:
Do not strike the bearing cap, as this may cause a propeller shaft imbalance.





12. Apply chassis lube grease to the U-joint and bearing caps provided in the sleeve yoke kit (listed in the PARTS INFORMATION section of this bulletin).

NOTE:
Do not apply an excessive amount of grease. Too much grease can cause incorrect snap ring selection.





13. Press-fit the bearing to the U-joint up to the position where the snap ring groove can be seen. Then press-fit the other bearing on the opposite side.





14. Install the snap rings (provided in the sleeve yoke kit) as follows:

a. Install a snap ring on one side. Press the bearing and U-joint into one side with a brass bar.

b. Install another snap ring of the same thickness to the opposite side.

c. Measure the clearance between the snap ring and the groove wall of the yoke with a feeler gauge. The clearance should be 0.01-0.03 mm (0.0004 - 0.001 in).





IMPORTANT:
Be sure the bearings are installed straight and that the universal joint pivots freely.

IF TRANSFER CASE REPAIR IS REQUIRED, GO TO STEP 18.

IF TRANSFER CASE REPAIR IS NOT REQUIRED, GO TO STEP 15 BELOW





15. Apply hypoid gear oil (SAE 75W-85W GL-4 or higher) to the outside of the sleeve yoke. Then reinstall the propeller shaft as described in Group 25 of the appropriate service manual.





! CAUTION
Take care to prevent scratching or damaging the rear oil seal. Be sure to align the mating marks previously made on the propeller shaft and the rear differential.





16. Tighten the transfer case drain plug and fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher).

a. Pour the oil slowly until oil level reaches the lower end of the filler hole (approximately 0.5 quart).

b. Attach the gasket to the filler plug. Install and tighten the filler plug.

17. Lower the vehicle.

TRANSFER CASE REPAIR





18. Drain the transfer case and remove it from the vehicle.

19. Remove all dirt and grease from the transfer case outer housing.

20. Remove the dust cover.

21. Remove the extension housing.

22. Remove the transfer case cover and O-ring.

23. Remove the drive bevel gear.





24. Inspect the bearing rollers and bearing race for abnormal wear (flaking).

a. If any signs of flaking are observed, replace the transfer case assembly. Do not continue with this repair procedure. Go to Step 43 for transfer case replacement instructions.





25. Check the drive gear for end play by hand. No end play should be felt. Rotate the drive gears by hand and check for unsmooth gear rotation.

a. If any play or unsmooth gear rotation are detected, replace the transfer case assembly. Do not continue with this repair procedure. Go to Step 43 for transfer case replacement instructions.





26. Remove the transfer case rear oil seal, using a flat-edge screwdriver.





27. Remove the transfer case front oil seal, using a flat-edge screwdriver.

28. To prepare for reassembly, clean dirt from the areas of the transfer case where the front and rear oil seals are installed.





29. Apply gear oil to the lip of the new front oil seal provided in the Transfer Case Repair Kit. Then install it into the transfer case. Using a plastic hammer, gently strike evenly around the seal. Then use special tool MD998304 to press-fit the seal into the case.

30. Apply gear oil to the lip of the new rear oil seal provided in the Transfer Case Repair Kit. Then install it to the extension housing. Using a plastic hammer, gently strike evenly around the seal. Then use special too MD998304 to press-fit the seal into the housing.

31. Apply additional gear oil to the front oil seal and install the drive gear to the transfer case.

! CAUTION
Be sure the beveled gear shaft is installed straight so that the oil seal does not fold over.





32. Apply gear oil to the new O-ring provided in the Transfer Case Repair Kit. Then install it to the transfer case cover.

33. Install the transfer case cover. Torque the bolts to 39 Nm (29 ft/lbs) in a crosswise pattern.

34. Remove sealant residue and oil from the contact surfaces of the transfer case adapter and extension housing.

35. Apply sealant (Mitsubishi Sealant MD997740) uniformly to the contact surface of the extension housing.





36. Install the extension housing to the transfer case. Torque the bolts to 39 Nm (29 if/lbs) in a crosswise pattern.

37. Fit the new rear dust cover provided in the Transfer Case Repair Kit to the extension housing.





38. Remove the breather plug. Remove sealant residue from the attaching surface of the extension housing. Apply sealant (3M Super Weatherstrip No. 8001 or equivalent) to the attaching surface.

39. Reinstall the breather plug to the extension housing. Be sure that the slanted end of the breather plug faces forward as shown above.

40. Reinstall the transfer case into the vehicle.





41. Tighten the transfer case drain plug and fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher).

a. Pour the oil slowly until oil level reaches the lower end of the filler hole.

b. Attach the gasket to the filler plug. Install and tighten the filler plug.

42. Lower the vehicle.

TRANSFER CASE REPLACEMENT





43. Remove the front exhaust pipe nuts.





44. Remove the transfer case subassembly.





45. Support the propeller shaft by tying it with a strong cord to prevent it from dangling.





46. Apply transfer case oil (hypoid gear oil SAE 75W-85W GL-4 or higher) to the outside of the sleeve yoke.

47. Install the sleeve yoke to the new transfer case. Refer to the PARTS INFORMATION section of this bulletin. Take care to prevent scratching or damaging the rear oil seal.





48. Install the new transfer case with the propeller shaft to the transaxle. Tighten the transfer case attaching bolts to the specified torque shown.





49. Tighten the front exhaust pipe nuts to the specified torque shown.

50. Fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher) until the oil level reaches the lower end of the filler hole (approximately 0.5 quart). Then lower the vehicle.