Transfer Case: Service and Repair

Fig. 11 Transfer Case & Extension Assembly:

Refer to Fig. 11 when performing the following procedure.

REMOVAL
1. Install transmission in a suitable holding stand.
2. Disconnect harness electrical connectors.
3. Remove transfer cover.
4. Remove shifter fork screw retaining the selector arm to shifter arm.
5. Remove transfer case and extension assembly.

INSTALLATION
1. Install transfer case and extension assembly.
2. Install selector arm to shifter arm and secure with shifter fork screw. Ensure shifter arm is caught by pawl of rod and selector arm is engaged with reverse check sleeve assembly.
3. Adjust neutral position as necessary by removing bolts holding reverse check sleeve assembly to case, move sleeve assembly outward and place adjustment shims between sleeve assembly and case to adjust clearance. When shim is removed, neutral position will move closer to reverse. When shim is added, neutral position will move closer to 1st gear. Use caution not to break O-ring when replacing shim. Also, if shims cannot adjust clearance, replace accent shaft and repeat adjustment.
4. Shift shifter arm to 5th and then to reverse to see if reverse check mechanism operates properly, then check to see if arm returns to neutral when released from reverse position. If arm does not return satisfactorily, replace reverse check plate.
5. Install transfer cover with gasket.
6. Connect harness electrical connectors.