JF2A Transfer Case

JF2A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: INSPECTION

INSPECTION

1. INSPECT TRANSFER INPUT SHAFT






(a) Using a micrometer, measure the diameter of the input shaft journal surface.
Minimum Diameter:
68 mm (2.68 in.)
If the diameter is less than the minimum, replace the input shaft.






(b) Using a dial indicator, measure the inside diameter of the input shaft bush.
Maximum Inside Diameter:
46 mm (1.81 in.)
If the inside diameter is more than the maximum, replace the input shaft.
2. INSPECT TRANSFER LOW PLANETARY GEAR ASSEMBLY






(a) Using a feeler gauge, measure the thrust clearance of the pinion gear.
Standard Clearance:
0.11 to 0.85 mm (0.00434 to 0.0334 in.)
Maximum Clearance:
0.85 mm (0.0334 in.)
If the clearance is more than the maximum, replace the low planetary gear assembly.






(b) Using a dial indicator, measure the radial clearance of the pinion gear.
Standard Clearance:
0.01 to 0.04 mm (0.000434 to 0.00150 in.)
Maximum Clearance:
0.04 mm (0.00150 in.)
If the clearance is more than the maximum, replace the low planetary gear assembly.
3. INSPECT REAR TRANSFER OUTPUT SHAFT






(a) Using a micrometer, measure the diameter of the output shaft journals.
Minimum Diameter:





If the diameter is less than the minimum, replace the output shaft.
4. INSPECT NO. 1 TRANSFER GEAR SHIFT FORK AND FRONT DRIVE CLUTCH SLEEVE






(a) Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
Maximum Clearance:
0.8 mm (0.0315 in.)
If the clearance is more than the maximum, replace the clutch sleeve or shift fork.
5. INSPECT AND ADJUST NO. 2 TRANSFER GEAR SHIFT FORK AND HIGH AND LOW CLUTCH SLEEVE






(a) Using a feeler gauge, measure the clearance between the clutch sleeve and gear shift fork.
Maximum Clearance:
3.15 mm (0.124 in.)
If the clearance is more than the maximum, replace the clutch sleeve or shift fork.
6. INSPECT NO. 1 SYNCHRONIZER RING






(a) Apply gear oil to the cone of the input shaft, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring.
If it can turn, replace the No. 1 synchronizer ring.






(b) Push the No. 1 synchronizer ring to the cone of the input shaft. Measure the clearance between the No. 1 synchronizer ring and input shaft.
Standard Clearance:
0.86 to 1.54 mm (0.0339 to 0.0606 in.)
Minimum Clearance:
0.86 mm (0.0339 in.)
If the clearance is less than the minimum, replace the No. 1 synchronizer ring with a new one.