Transfer Case: Inspection

Replace any worn or damaged parts. Measure detent ball spring length. Standard spring length is .768" (19.5 mm). Replace any spring that measures less than .709" (18.0 mm) in length. Replace all seals and "O" rings. Measure shift fork-to-sleeve clearance. See Fig 1 . Replace shift fork if clearance exceeds .039" (1.0 mm).

Fig 1: Measuring Shift Fork-To-Sleeve Clearance

Courtesy of SUZUKI OF AMERICA CORP.