Transfer case disassembled
2. Measure the clearance in the transfer case gear.
Standard: 0.06-0.16mm
Measuring the total starting torque
3. Rotate the coupling flange several times to seat the tapered roller bearing.
4. Measure the total starting torque (from the connecting flange side) using a torque wrench.
Note: To avoid damaging the transfer case housing, always secure it in a soft jawed vice or use a spacer between the vice and the transfer case.
Standard: 2.24-3.71 Nm (22.0-36.4 kgf·cm)
Checking the contact patch in the transfer case drive gear
5. Remove the transfer case from the vice.
6. Remove the transfer case holder assembly (A) from the transfer case housing (B), then remove the dowel pin (C) and O-ring (D).
7. Apply a thin layer of red lead evenly to both sides of the transfer case drive gear teeth.
8. Install the transfer case bracket assembly onto the transfer case housing, then tighten the bolts.
9. Rotate the coupling flange in both directions until the transfer case gear has turned one full revolution in both directions.
10. Check the contact patch on the transfer case gear teeth.
11. If the contact patch location is different from the norm, disassemble the transfer case, replace worn or damaged parts and reassemble it.