Inspection and Repair
Inspection and Repair
1. Make the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection.
2. Wash all parts thoroughly in clean solvent. be sure all old lubricant, metallic particles, dirt, or foreign materials are removed from the surface of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.
Inspection and Repair (Transfer Case Assembly)
When wear, damage, or any other defects are observed during inspection, the part or parts must be repaired or replaced. Wash all parts with clean detergent, amd check that old oil, metallic particles, dirt, or foreign materials are completely removed. Blow compressed air into oil holes and grooves to remove foreign materials and residual detergent.
Chain
- Check whether the face that contacts the sprocket is free from excessive wear or damage. If defects are observed, replace the part.
- If a chain interference mark is found on the inside wall of the transfer cover or there is so much slack in the chain that a skipped engagement occurs between the chain and sprocket, replace the chain.
Sprocket
- Check whether the sprocket tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part.
Gear
- Check whether the gear tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline.
- Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part.
2-4 and Neutral Switch
- Check the continuity of 2-4 and neutral switch. If defects are observed, replace the 4H and 4L switch.
2-4 Switch Signal
Terminal 1-2
Switch stroke 1: Open
Switch stroke 2: Close
Neutral Switch Signal
Terminal 1-2
Switch stroke 1: Close
Switch stroke 2: Open
Oil Pump
- Remove foreign materials from the strainer. If the strainer is damaged, replace it. If the area into which the shaft is inserted is excessively worn or damaged, replace the oil pump assembly.
Clutch Hub Spline Play
- Set a dial indicator to the clutch hub to be measured.
- Move the clutch hub as far as possible to both the right and the left.
- Note the dial indicator reading.
- If the measured value exceeds the specified limit, the clutch hub must be replaced.
Clutch Hub Spline Play
Standard 0-0.1 mm (0-0.004 in.)
Limit 0.2 mm (0.008 in.)
Bearings
- Inspect the condition of all needles and ball bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers.
- Lubricate the bearings with a light oil and check the for roughness by slowly turning the race by hand.
Ball Bearing Play
- Use a dial indicator to measure the ball bearing play.
- If the measured value exceeds the specified limit, the ball bearing must be replaced.
Limit 0.2 mm (0.008 in)
Synchronizers
The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled.
Clean synchronizer components with clean solvent and air dry.
Inspect the components for the following:
- teeth for wear, scuffs, nicks, burrs or breaks.
- Keys and springs for wear, cracks or distortion. Replace if these conditions exist.
- If scuffed, nicked or burred conditions cannot be corrected with a sift tone or crocus cloth, replace the component.
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance between the block ring and the insert.
2. The measured value exceeds the specified limit, the block ring and the insert must be replaced.
Clearance
Standard 3.86-4.14 mm (0.152-0.163 in.)
Limit 4.9 mm (0.193 in.)
2WD-4WD Synchronizer (3-Cone)
1. Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the 2WD-4WD synchronizer assembly must be replaced.
Block Ring and Dog Teeth Clearance
Standard1.5 mm (0.059 in.)
Limit 0.8 mm (0.031 in.)
Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance between the clutch hub and insert.
2. If the measured value exceeds the specified limit, the clutch hub and insert must be replaced.
Clutch Hub and Insert Clearance
Standard 0.01-0.18 mm (0.0004-0.0075 in.)
Limit 0.3 mm (0.012 in.)
Detent Springs
1. Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.
Detent Spring Free length
1. Use a vernier caliper to measure the detent spring free length.
2. If the measured value is less that the specified limit, the detent spring must be replaced.
Detent Spring Free Length
Standard 23.4 mm (0.92 in.)
Limit 22.8 mm (0.90 in)
Detent Spring Tension
1. Use a spring tester to measure the detent spring tension.
2. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent Spring
Compressed height 18.7 mm (0.736 in.)
Standard 68.6-88.2 N (15.4-19.8 lb.)
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring. Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit, the shift arm must be replaced.
H-L Shift Arm
Thickness:
Standard 7.6-7.85 mm (0.299-0.309 in.)
Limit 7.0 mm (0.276 in.)
2-4 Shift Arm
Thickness:
Standard 9.6-9.85 mm (0.378-0.388 in.)
Limit 9.0 mm (0.354 in.)