Transfer Case: Overhaul: Overhaul: Inspection

Check the internal and external gear teeth and sleeve for signs of wear or damage. Check gearshift locating spring free length. Standard free length should be .933" (23.7 mm). Service limit should be .866" (22.0 mm). Ensure bearings rotate smoothly and are not damaged. Check shift shafts for wear or damage. Replace any worn or damaged part. Measure the side clearance of gears. See Fig 1 . See GEAR SIDE CLEARANCE SPECIFICATIONS  table. Check lower end of gearshift lever for wear or damage.

Fig 1: Measuring Gear Side Clearance

Courtesy of SUZUKI OF AMERICA CORP.