A. Inspect Transfer Case

1. Road test the vehicle to check for any abnormal noise or grinding sounds from the transfer case. If any abnormal noises or grinding sounds are heard, the transfer case must be replaced. (Ignore normal gear noise such as high pitch whine.)

2. Raise the vehicle on an appropriate hoist.





3. Remove the transfer case oil filler plug. Check the amount of oil in the transfer case by inserting the transfer case oil level gauge (PN MR470416) into the oil filler hole (Figure 1).

^ If the transfer case oil level registers anywhere on the gauge, the oil level is sufficient, continue with Step 5.

^ If the transfer case oil level does NOT register on the gauge, continue with Step 4.

NOTE:
If fill plug shows signs of leakage, replace the fill plug gasket.





4. For all vehicles with low oil levels: Remove the transfer case oil drain plug (Figure 2).

^ If oil runs out or drips continuously, transfer case replacement is NOT required.

^ If NO OIL or only A FEW DROPS OF OIL come out, the transfer case MUST be replaced. Continue with Section B.

NOTE:
If drain plug shows signs of leakage, replace the drain plug gasket.





5. Inspect the driveshaft yoke plug and front exhaust pipe (Figure 3) for signs of oil leakage. If signs of leakage from the yoke are evident, the driveshaft yoke must be replaced.

6. Inspect the transfer case for indications of any oil leakage. Any transfer case oil leak must be repaired.

7. ^ If the driveshaft yoke, input and/or output shaft oil seal, andlor transfer case require replacement, continue with Section B.

^ If the transfer case oil leak is from a component that requires transfer case disassembly (case upper cover gasket, gear case 0-ring, front case driveshaft cover 0-ring or reseal case-to-extension housing), refer to the service manual for the repair procedure.

^ If the transfer case does NOT require replacement and there are no signs of oil leakage:

A. Reinstall the transfer case drain plug (if removed).

B. Fill the transfer case with hypoid gear oil (SAE 75W-85W GL-4 or higher) (Figure 2).

C. Install the transfer case oil filler plug.

D. Lower the vehicle and return it to the customer. No further action is required.