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Transfer Case Output Flange Runout Measurement

WARNING: This page is about a different car, the 2007 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool 

J 7872 Magnetic Base Dial Indicator Set, or equivalent 

NOTE: This measurement procedure is intended to measure transmission or transfer case output flange runout for systems with a constant velocity (CV) joint, rubber coupling or bolt-on U-joint yoke at the transmission or transfer case.
  1. Place the transmission in NEUTRAL.
  2. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  3. If equipped with a CV joint, measure the transmission or transfer case output flange radial runout on the machined surface of the prop shaft front CV joint housing, as close to the flange as possible:
    1. Clean the surface of the prop shaft front CV joint housing just rear of the transmission or transfer case output flange.
    2. Mount a dial indicator set, J 7872, or equivalent, and position the dial indicator to contact the prop shaft front CV joint housing as close to the transfer case output flange as possible.
  4. If equipped with a rubber coupling or bolt-on U-joint yoke, measure the transfer case output flange radial runout on the machined surface of the flange pilot area:
    1. Mark the position of the prop shaft to the transmission or transfer case output flange.
    2. Separate the prop shaft from the transmission or transfer case output flange.
    3. Clean the surface of the flange pilot area.
    4. Mount a dial indicator set, J 7872, or equivalent, and position the dial indicator to contact the pilot area as close to the end of the pilot as possible.
  5. Rotate the transmission or transfer case output flange by hand to locate the low spot.
  6. Set the dial indicator to zero on the low spot.
  7. Rotate the flange or shaft by hand and record the amount of radial runout.
  8. Compare the runout of the flange or shaft to the runout tolerance specifications guideline.
  9. If the transmission or transfer case output flange runout exceeds the specification, the flange or shaft requires replacement.
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