Warning!
- Make sure the lifts, jacks and safety stands are installed correctly (see chapter 1).
- Apply the parking brake and block the rear wheels so that the vehicle does not roll off the bed and fall on you while you are working under it.
1. Raise the front of the vehicle and secure it securely.
2. Set the parking brake and chock both rear wheels.
3. Shift into neutral.
4. Mark the propeller shaft and transfer case coupling flange assembly.
5. Separate the propeller shaft from the transfer case assembly.
6. Install the indicator head on the transfer case flange, then measure the clearance in the transfer case gear engagement. Standard: 0.06-0.16mm.
7. If the clearance is out of specification, remove the transfer case assembly and adjust the clearance of the transfer case gear (see below).
8. Check the transfer case assembly for damage and fluid leakage.
- If fluid is leaking between the crankcase and transfer case cover, remove the transfer case cover and replace the O-ring.
- If fluid is leaking between the flywheel and transfer case housing, remove the transfer case assembly and replace the O-ring.
- If fluid is leaking between the transfer case coupling flange and the oil seal, remove the transfer case assembly and replace the oil seal and O-ring on the transfer case shaft. If oil seal replacement is required, assemble the transfer case and inspect and adjust the shape of the transfer case gear contact pattern, transfer case gear mesh clearance, tapered roller bearing starting torque, and total starting torque (see below).
- Do not replace the oil seal on a transfer case installed on the gearbox.