Transfer Case: Inspection
Clean all internal components and case sections in solvent and dry thoroughly. Inspect case sections for cracks and porosity. Inspect all gears and sprockets for excessive wear and broken or chipped teeth. Inspect shift shafts and shift forks for excessive wear or damage. Inspect all bearings for smooth rotation. Inspect drive chain and sprockets for excessive wear or damage. Replace any worn or damaged parts as necessary. Using outside calipers, measure detent ball spring length. Standard spring length is .768" (19.5 mm). Minimum serviceable spring length is .709" (18.0 mm). Replace all seals and "O" rings. Using feeler gauge, measure shift fork-to-sleeve clearance. See Fig 1 . Replace shift fork or clutch sleeve if clearance exceeds .039" (1.0 mm).
Assemble synchronizer inner and outer rings and cone. Using feeler gauge, measure difference between inner and outer rings. If difference is greater than .039-.055" (1.0-1.4 mm), replace synchronizer. Measure synchronizer outer ring key slot width. If key slot width exceeds 0.397" (10.1 mm), replace outer ring.