Transfer Case: Testing and Inspection

A/T Transfer Assembly Inspection In-vehicle

1. Raise the vehicle on a lift, and make sure it is supported securely.

2. Shift the transmission into N.

3. Make a reference mark (A) across the No. 1 propeller shaft (B) and the transfer companion flange (C).

4. Separate the No. 1 propeller shaft from the transfer assembly.






5. Set a dial indicator (A) on the transfer companion flange (B), and measure the transfer gear backlash.





6. If the backlash is out of standard, remove the transfer assembly, and adjust the transfer gear backlash. A/T Transfer Assembly Reassembly (4WD, A/T)

7. Check for fluid leaks between the mating surfaces of the transfer assembly and transmission.

8. If there is a leak, remove the transfer assembly, and replace the O-ring. Also check for fluid leaks between the mating surfaces of the transfer housing and transfer cover. If there is a leak, remove the transfer assembly, and replace the O-ring.

9. Check for leaks between the transfer companion flange and transfer oil seal.

10. If there is a leak, remove the transfer assembly from the transmission, and replace the transfer oil seal and O-ring on the transfer output shaft. If oil seal and O-ring replacement is required, you will need to check and adjust the transfer gear tooth contact, transfer gear backlash, the tapered roller bearing starting torque, and the total starting torque. Transfer Assembly Inspection - Out-of-Vehicle (4WD, A/T) Do not replace the oil seal with the transfer assembly on the transmission.